Ford F150 Pickup. Instruction — part 77

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consists of a 60-pin module, a bracket, a marine cover and four marine cover retainers.

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houses the unique electronics required for natural gas fuel systems.

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is located on the center radiator support, behind the radiator grille.

The NGV module (9F954) carries out the following functions:

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injector drivers: the NGV module accepts eight unmodified injector signals from the powertrain control
module (PCM) (12A650) and allows a peak-and-sustain current to flow through the injector solenoids.

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fuel gauge driver: the NGV module uses tank temperature and fuel tank pressure inputs to calculate the
density of the fuel; a look-up table is used to determine the output signal to the fuel gauge.

Fuel Tank Pressure Sensor

The fuel tank pressure sensor (9C052):

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contains integral solid state circuitry that outputs a voltage signal that is proportional to pressure.

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has an output that is linear from 344.74 kPa (50 psi) up to 27,579.03 kPa (4000 psi).

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is mounted in the rear in-bed fuel tank solenoid valve.

Tank Temperature Sensor

The tank temperature sensor:

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changes resistance in response to the temperature of the fuel in the fuel tank; as the surrounding
temperature increases, the resistance decreases (the voltage signal also decreases).

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provides a signal to the NGV module that indicates the temperature of the fuel.

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is mounted in the rear in-bed fuel tank solenoid valve.

Diagnostic Instructions

The NGV module monitors the components and circuitry required for fuel indication during normal operation.
If an error or concern is detected, the NGV module will store a diagnostic trouble code (DTC) in memory.
DTCs are retrieved from the NGV module using the diagnostic tool. If a concern exists with the instrument
cluster that is not related to the fuel indication system, refer to INSTRUMENT CLUSTER-
CONVENTIONAL - F150 . DO NOT carry out NGV module diagnostics. The components monitored by the
NGV module include:

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the tank temperature sensor

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the fuel tank pressure sensor

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the fuel gauge (part of the instrument cluster)

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the circuitry

NOTE:

No injector calculations are carried out; the injector driver output is not
determined by the NGV module.

2003 Ford Pickup F150

2003 ACCESSORIES AND BODY, CAB Instrument Cluster-Natural Gas - F150

Fuel gauge accuracy can be affected by certain conditions. These conditions will cause abnormal fuel gauge
movement, possibly causing unnecessary diagnostics. Make sure the following conditions do not exist before
continuing with fuel indication system diagnostics:

A. Fast filling

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After fast filling a vehicle, the fuel gauge reading can drop as much as 1/16 of a tank. This is
caused by the rapid expansion and compression of the fuel during fast fills. This is considered
normal gauge movement.

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Fast filling with the ignition switch in the RUN position can cause the NGV module to store DTCs
in error. With the ignition switch in the RUN position, the NGV module is monitoring the sensors.
During fast fill situations, the tank temperature drops to extremely low temperatures; this may
cause the tank temperature sensor to drop below its operating temperature range, causing the NGV
module to store a DTC. When fast filling is complete, the tank temperature sensor will return to
normal operation after it reaches normal operating temperature range. However, the DTC will still
be stored.

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Fast filling with the ignition switch in the RUN position will cause the fuel gauge to move very
slowly toward Full; this is eliminated when the vehicle is filled with the ignition switch in the OFF
position.

B. Fuel system leaks

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Fuel leaks can cause inaccurate fuel gauge readings. Depending on the size of the leak, the fuel
gauge may not be able to maintain an accurate reading if the fuel leak exceeds the instrument
cluster and NGV module's ability to update the fuel gauge. This creates a possibility for the fuel
gauge to display a fuel level when the fuel tanks are empty. Before diagnosing this type of concern,
make sure the fuel system is not leaking.

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After repair of a fuel system that has been drained, the fuel gauge will display Empty during the
initial key-on of the ignition switch since there is no pressure in the fuel lines. After 4-5 key-ons,
the fuel gauge will display the appropriate reading.

Inspection and Verification

1. Verify the customer concern by operating the instrument cluster (10849) to duplicate the condition.

Observe the indicators, warning displays, and gauges to determine if they are operating correctly with the
ignition switch:

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in RUN with the engine off.

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in START before the ignition switch is released.

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in RUN with the engine running.

2. Visually inspect for obvious signs of mechanical and electrical damage:

NOTE:

Refer to FUEL SYSTEM LEAK TEST for the Fuel System Leak Test.

NOTE:

When installing a new instrument cluster reset the PCM ID and carry out the
PATS parameter reset procedure. Refer to THE INSTRUMENT CLUSTER
PARAMETER AND PCM ID RESET PROCEDURE .

2003 Ford Pickup F150

2003 ACCESSORIES AND BODY, CAB Instrument Cluster-Natural Gas - F150

Visual inspection chart

Fig. 5: Visual Inspection Chart Of Mechanical And Electrical Damage
Courtesy of FORD MOTOR CO.

3. If the inspection reveals obvious concern(s), repair as necessary.

4. If the cause of the concern is not visually evident, proceed to the next step.

5. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC)

located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If
the diagnostic tool does not communicate with the vehicle:

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Check that the program card is correctly installed.

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Check the connections to the vehicle.

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Check the ignition switch position.

6. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool instruction.

7. Carry out the DATA LINK DIAGNOSTIC TEST. If the diagnostic tool responds with:

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CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to MODULE
COMMUNICATIONS NETWORK .

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NO RESP/NOT EQUIP for NGV module, go to Pinpoint Test J.

2003 Ford Pickup F150

2003 ACCESSORIES AND BODY, CAB Instrument Cluster-Natural Gas - F150

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NO RESP/NOT EQUIP for HEC, go to Pinpoint Test L.

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SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the
continuous DTCs and carry out self-test diagnostics for the NGV and HEC module.

8. If the DTCs retrieved are related to the concern, go to the HEC Diagnostic Trouble Code (DTC) Index, or

the NGV Module Diagnostic Trouble Code (DTC) Index to continue diagnostics.

9. If no DTCs related to the concern are retrieved, proceed to the HEC Dealer Test Mode to continue

diagnostics.

Instrument Cluster Parameter and PCM ID Reset Procedure

1. Connect battery (last step in the removal and installation procedure).

2. Carry out the PATS parameter reset procedure. Refer to ANTI-THEFT - PATS .

3. Disconnect the battery.

4. Wait three minutes to clear the PCM keep alive memory then reconnect the battery.

5. Position the first PATS key to run for three seconds. Within three seconds, remove and insert the second

PATS key and position to run for three seconds. This will store both PATS keys and the PCM ID into the
new HEC module.

HEC Dealer Test Mode

To enter the HEC Dealer Test Mode, depress and hold the instrument cluster SELECT/RESET button and then
turn the ignition switch to the RUN position. Continue pressing the SELECT/RESET button (five seconds) until
EST is displayed in the odometer. The SELECT/RESET button must be released within three seconds of the
odometer displaying test to begin the dealer test mode. Depress the SELECT/RESET button to advance through
the following steps until the dtc is displayed. Depressing the SELECT/RESET button will display any
continuous DTCs stored before proceeding to the next step.

NOTE:

Following installation of the new instrument cluster, it is necessary to reset the
PCM ID and carry out the PATS parameter reset procedure. Refer to ANTI-
THEFT - PATS .

2003 Ford Pickup F150

2003 ACCESSORIES AND BODY, CAB Instrument Cluster-Natural Gas - F150