Ford F150 Pickup. Instruction — part 1345

Fig. 7: Identifying Fuel Pump Relay Harness Connector Terminals
Courtesy of FORD MOTOR CO.

1. Remove fuel pump (valve) relay. See FUEL PUMP RELAY LOCATION table. Connect a jumper wire

between fuel pump relay cavities No. 30 and 87. See Fig. 7. This will cause tank valves to open and
pressurize fuel system. Remove jumper wire and go to next step.

FUEL PUMP RELAY LOCATION

2. Reinstall fuel pump relay. Using Combustible Gas Detector (134-00049), check spring lock coupling and

Application

Location

Crown Victoria

In Relay Center Box No. 1, On Left Side Wheelwell In Engine Compartment

Econoline

In Battery Junction Box, On Left Side Of Engine Compartment

F150

In Battery Junction Box, On Rear Left Side Of Engine Compartment

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE System & Component Testing - CNG

fuel injection supply manifold to fuel injector connections for leaks. If a leak is detected, verify
connection is engaged properly, then retest. If leak remains, repair as necessary and retest.

Fuel Tanks, Filter & Lines

Using combustible gas detector, check fuel tank(s), coalescent filter and fuel line connections for leaks. If a leak
is detected, verify that fittings are tightened properly, then retest. If leak is still present, inspect "O" ring, "O"
ring seat and sealing surfaces for any damage, distortion or contamination. Repair as necessary and retest.

Rear/Upper Fuel Tank Rack Vapor Vent Box (Crown Victoria)

1. Install the Rotunda Pressure Test Adaptor (134-00122 - part of NGV Pressure and Venting Kit) to the

upper tank rack flexible vent tube. Install the Rotunda Evaporative Emission Tester (134-00056) to the
pressure test adaptor.

2. Pressurize the vapor vent box to 17 in. H2O (5 kPa).

3. Monitor the pressure for two minutes. The pressure should not drop more than 6 in. H2O (1.5 kPa).

4. If the pressure drops in excess of 6 in. H2O (1.5 kPa), apply a soapy water solution around the vapor vent

box gasket and seals to pinpoint the leak. Install a new gasket or seals as applicable.

FUEL TANK INSPECTION (IN-VEHICLE)

1. Raise and support vehicle. Examine vehicle underbody and chassis in general area near fuel tank(s) for

any indication of collision damage, malfunction, fire or excessive mud/dirt accumulation. Examine fuel
tank stone/heat shield for any indication of collision damage, malfunction, fire or excessive mud/dirt
accumulation. Remove fuel tank stone/heat shield. Examine fuel tank(s) and stone/heat shield interior for
any foreign objects (such as stones or gravel) or foreign materials (such as mud, salt, liquids or chemical
residue).

2. Remove any foreign material, using only a clean, dry cloth. Remove all foreign objects. DO NOT use

water or any cleaners. Examine fuel tank labels for tank expiration date. Use a light and mirror to access
labels hidden from normal view. If expiration date has been exceeded, condemn tank, using procedures in
step 8.

3. Inspect tank sidewall and dome ends, following general guidelines set forth in Compressed Gas

Association Pamphlet C6.2. Inspect tank(s) for abrasions, dents, cracking, blistering or peeling of clear

NOTE:

Verify system pressure is no less than 1500 psi (105.5 kg/cm

2

). If system

pressure is less than 1500 psi (105.5 kg/cm

2

), refuel vehicle.

NOTE:

The following procedure is an in-vehicle visual inspection for natural gas fuel
cylinders. A 3 year, 36,000-mile (whichever occurs first) inspection interval is
assumed.

NOTE:

Compressed Natural Gas Pamphlet C6.2 can be obtained from
Compressed Gas Association, Inc., 1725 Jefferson Davis Highway,
Arlington, VA 22202-4102.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE System & Component Testing - CNG

coating, corrosion, cracks or gouges in metal dome, cracks in fiberglass overwrap, impact damage
(cracking) in fiberglass overwrap, cuts or gouges in fiberglass overwrap, exposed fibers, delamination
(separating) of fiberglass overwrap, discoloration of fiberglass overwrap, and/or fire or heat damage, such
as charring or discoloration.

4. If any flaws are detected, measure depth and length of flaw in accordance with Compressed Gas

Association Pamphlet C6.2 guidelines. If any of the flaws cannot be completely measured in vehicle, tank
must be removed from vehicle for further inspection. If tanks have been or are suspected of having been
exposed to a corrosive chemical spill, tank must be removed from vehicle for further inspection of
complete composite surface, including area under tank straps. If there is any indication of chemical
attack, such as blistering, cracking or delamination, tanks must be condemned and replaced with new
tanks.

5. The acceptance criteria for cuts and abrasions are different from those listed in Section 6.5.1 of

Compressed Gas Association Pamphlet C6.2. These tanks have extra epoxy resin and a clear coat to
reduce sensitivity to surface damage. The following are composite wrap inspection criteria:

z

Level 1 Abrasions

These are defined as minor abrasions, such as scuffs less than .010" (0.254 mm) deep, and are
acceptable without repair.

z

Level 2 Abrasions

These are defined as abrasions having some exposed fibers or flat spots with a depth between .010-
.030" (.254-.762 mm). Level 2 abrasions must be repaired before tank is returned to service.

z

Level 1 Cuts

These are defined as cuts or scratches less than .010" (.254 mm) deep and are acceptable without
repair regardless of length, number or direction.

z

Level 2 Cuts

These cuts have a maximum depth of .030" (.762 mm) and a maximum length of 8" (203 mm).
Level 2 cuts must be repaired before tank is returned to service.

6. Repair damage to composite wrap as follows:

z

Level 2 cuts and abrasions are to be coated with epoxy resin. Mix and apply commercial room
temperature cure, 2-component epoxy resin according to manufacturer's instructions. Frayed fibers
must be cut away before application of epoxy resin.

z

Tanks with damage exceeding Level 2 must be condemned using procedures in step 8.

z

The criteria for other damage to composite wrap are defined in Compressed Gas Association
Pamphlet C6.2.

7. The metal tank ends are protected with a multi-coat system using epoxy and polyurethane coatings. Chips

in coating must be evaluated and repaired. Metal tank end external inspection criteria are as follows:

z

Level 1 Chips

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE System & Component Testing - CNG

These are chips or abrasions which do not penetrate Black epoxy coating. The steel or Gray primer
has not been exposed. Level 1 chips require no repair.

z

Level 2 Chips

These are chips or abrasions which penetrate Black epoxy coating and must be repaired as follows
to prevent corrosion:

a. Sand damaged area to remove rust and rough up surrounding coating.

b. Clean damaged area with a commercial pre-paint cleaning solvent.

c. Apply a zinc-rich, cold galvanizing compound (Rust-Oleum(tm) Zinc-Rich or equivalent

commercial product).

z

Dents

Tanks with dents to metal ends which are more than .060" (1.524 mm) in depth must be removed
from service and condemned using procedures in step 8.

z

Gouges

Tanks with sharp gouges penetrating coating and into metal liner must be removed from service
and condemned using procedures in step 8.

8. Condemned tanks, whether due to damage or expiration, shall be removed from vehicle and destroyed as

follows:

a. Vent and remove fuel tanks. See appropriate REMOVAL & INSTALLATION article.

b. Remove fuel tank solenoid valve. See appropriate REMOVAL & INSTALLATION article.

c. Purge fuel tank with compressed air for 30 seconds.

d. Destroy fuel tank by drilling a .50" (12.7 mm) diameter hole in fuel tank sidewall.

9. Examine fuel tank straps for correct positioning of rubber isolators. Replace rubber isolators as necessary.

When completed, record date, vehicle mileage and results of fuel tank inspection.

UNABLE TO VENT FUEL TANKS OR FUEL LINES

Pre-Inspection

WARNING:

When venting Compressed Natural Gas (CNG) from system, fuel filler
neck venting kit must be connected to a vent stack that allows CNG to be
vented outside of repair shop. Vent stack installation must be approved
by local authorities.

NOTE:

A DVOM, New Generation Star (NGS) tester and NGV Pressure and Venting Kit
(134-00114) are necessary to perform the following test procedures. NGV
pressure and venting kit includes Rotunda Fuel Filler Neck Venting Kit (134-
00117), Grounding Cable (134-00121), Electrical Harness for Venting Tanks (134-

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE System & Component Testing - CNG