Ford Falcon. Manual — part 184
303-04c-24
Single Fuel LPG
303-04c-24
DIAGNOSIS AND TESTING (Continued)
Relief Valve
Condition
Source
Action
Leaking (Note:This is normal if tank
Foreign matter caught between seat.
Replace relief valve.
pressure is above 2.5 MPa)
Defective seat.
Replace relief valve.
Inadequate spring tension.
Replace relief valve.
LPG Gauge & Sender Unit
Condition
Source
Action
Inaccurate tank reading.
Defective sender.
Replace sender.
Misaligned gearing.
Replace float arm.
Remains at empty.
Defective sender.
Replace sender.
Defective float arm.
Replace float arm.
Wiring fault.
Check and rectify wiring.
Leaking gas.
Defective gasket.
Replace gasket.
Dash-mounted fuel gauge
Condition
Source
Action
No indication.
Empty fuel tank.
Refill tank.
Broken/disconnected wire.
Check wiring.
Grounded wire from sender.
Check wiring.
Sender not earthed.
Check earthing connection & PCM
Sender defective.
Replace sender.
Erratic reading.
Loose connection.
Tighten connection.
Defective sender.
Replace sender.
Reads full at all times.
Short in wiring.
Check wiring.
Defective sender.
Replace sender.
Inaccurate reading.
Defective sender or gauge.
Replace defective part.
Receiver incompatible with sender.
Check resistance in ohms.
Functional Diagnosis
Condition
Probable Cause & Rectification
Hints / Cautions
Driveability issues such Replace Ram-Air Balance Tube if
A small crack or hole in the Balance
as stalling, roughness
damaged. Refit if simply dislodged.
Tube, often difficult to see, will cause a
of operation, flat spots,
driveability issue.
hesitations, surges, etc.
Remove & clear Ram-Air Balance Tube
Ensure care is taken not to damage
of water, grass, etc. Refit.
Balance Tube during this process (see
above).
Replace Air Filter if dirty. Ensure Air
A dirty Air Filter will cause driveability
Cleaner & Springs are installed correctly. issues. Always reset KAM after it is
replaced.
Clear contaminant/blockage from idle jet. The idle jet plays an important role
Refit.
throughout the driving range – not just
at idle.
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303-04c-25
Single Fuel LPG
303-04c-25
DIAGNOSIS AND TESTING (Continued)
Condition
Probable Cause & Rectification
Hints / Cautions
Inspect & clean the mesh within the
This requires high pressure liquid LPG
Filter/Lock-off at Converter. Refit.
work and must, therefore, be conducted
by a registered technician.
Check for leaks in the Intake System
A small vacuum leak from the intake
between the Air Filter Element and the
Manifold or any vacuum assisted
Gas-Air Mixer, Intake Manifold or PCV
component will lean out the air/fuel
System. Rectify all leaks.
mixture causing driveability issues.
Check condition of PCV Valve. Replace if If the PCV Valve is broken, check the
damaged or faulty.
Valve Cover for fragments. They will be
held within a baffle.
If insufficient supply of LPG is making it
Prior to working on components
to the converter, ensure both Manual
associated with high pressure liquid
Isolating Valves on each LPG Tank
LPG, always run the vehicle with the
Service Valve are fully open and the
Manual Isolating Valve closed until the
condition and security of steel Bundy
engine stalls to ensure no LPG remains
tubes is satisfactory. Rectify any damage after the Service Valve.
or leaks. If there is no fault found
externally, the Service Valve and its
Strainer or a blockage within the Bundy
tubes could be the problem. Replace the
Service Valve or clear the blockage as
required.
Drain contaminant from converter whilst
Draining a hot converter will allow those
still hot from recent LPG operation. Refit
contaminants that solidify when cool to
both drain plugs.
be drained as well. However,
precautions must be taken against
burns.
Check Secondary Chamber within the
Gently pushing on the metal plate in the
Converter retains pressure for at least 10 centre of the Secondary Diaphragm
minutes after recent LPG operation. If
through the hole in the Converter
not, recondition or replace converter.
outboard shell should result in an
Note: Converter-related warranty claims
audible release of pressure. The metal
require a Ford Prior Approval No. to be
plate should move in without
issued.
notchiness, indicating that the pin
behind it isn’t sticking.
Contamination, damage or
Do not Key On with the Stepper Motor
electrical/mechanical fault within Stepper removed from its mounting body. It will
Motor leading to Stepper Motor seizure.
reset which involves full extension and
Replace Stepper Motor.
subsequent loss of the Pintle.
Wiring or connector damage or fault
The NGS has a built in Self Test to
between Stepper Motor and PCM leading check fuel control. Stepper Motor
to Stepper Motor seizure, reversal of
position can also be monitored - most
direction or stutter. Rectify wiring or
usefully with HEGO voltage.
connector problem.
PCM not providing correct signals to
Swapping PCMs to check for
Stepper Motor. Replace PCM.
functionality where PATS/BETS is
active cannot be done.
Check Ignition System components for
A slight ignition breakdown under load is
function and security.
significant with LPG.
Backfiring
Rectify problem with Ignition System.
A lean mixture increases the likelihood
Check spark plug specification, gap and
of a backfire with a poor Ignition
condition. Ensure COILS are in good
System, but is not the true cause of the
condition.
problem.
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303-04c-26
Single Fuel LPG
303-04c-26
DIAGNOSIS AND TESTING (Continued)
Condition
Probable Cause & Rectification
Hints / Cautions
Water comes out of
Repair or replace Converter. Note:
Cooling System maintenance is
vapour hose or
Converter - related warranty claims
extremely important in all
converter drain plugs
require a Ford Prior Approval No. to be
Converter-based LPG systems. Check
issued. Rectify Cooling System fault or
engine doesn’t overheat or run cool.
blockage. Check Coolant quality and
level.
Poor fuel economy
Monitor HEGO Sensor and Stepper
Engine Earth Straps and the HEGO
Motor position during idle, Acceleration,
Sensor are critical to efficient operation
Cruise and Deceleration. Ensure both are on LPG. Complete intake system
operating within normal ranges.
sealing and Air Filter Element condition
are also important for efficient operation
on LPG.
Poor starting
Check for deposits / contamination in the Refer above.
converter.
Verify Prime Valve operation on
Note that the Prime Valve operates
Cranking.
between 300-700 ms on Cranking but
there are certain situations where there
will be no prime operation.
All
Check sensitive diaphragm (under front)
The diaphragm must be free to move
cover for sludge or deposits
without sticking to the converter or being
weighed down.
NOTE: Leak test the LPG system after any
maintenance on LPG high pressure areas. Reset
KAM after any maintenance of the LPG system.
Connector Circuit Reference
LPG Converter C-913
Pin Number(s)
Circuit Designation/Description
Normal Condition/Measurement
1
Circuit 16H / (R-G)
0 voltage when ignition OFF, Greater than 10
Primary Lockoff power circuit
volts when engine cranking and running. Greater
than 10,000 ohms between lockoff and ground.
2
Circuit 57Y / (B)
0 voltage, less than 5 Ohms to chassis ground.
Secondary Lockoff ground circuit
3
Circuit 16X / (R-G)
0 voltage when ignition OFF, Greater than 10
Secondary Lockoff power circuit
volts when engine cranking and running. Greater
than 10,000 ohms between lockoff and ground.
4
Circuit 1500 / (B)
0 voltage, less than 5 ohms between solenoid
Primary Solenoid ground circuit
and EEC-C Pin C21 PRIM.
5
Circuit 57X / (B)
0 voltage, less than 5 Ohms to chassis ground
Primary Lockoff ground circuit
6
Circuit 592 / (W) S
12 volt square wave when measured across pin
tepper Motor Driver circuit
591 and 592. Greater than 10,000 ohms
between stepper motor and ground
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303-04c-27
Single Fuel LPG
303-04c-27
DIAGNOSIS AND TESTING (Continued)
Pin Number(s)
Circuit Designation/Description
Normal Condition/Measurement
7
Circuit 594 / (BR-B)
12 volt square wave when measured across pin
Stepper Motor driver circuit
593 and 594. Greater than 10,000 ohms
between stepper motor and ground
8
Circuit 361D / (R)
0 voltage when ignition OFF, Greater than 10
Primary Solenoid power circuit
volts when ignition ON and engine cranking and
running. Greater than 10,000 ohms between
solenoid and ground
9
Circuit 591 / (BR)
12 volt square wave when measured across pin
Stepper Motor driver circuit
591 and 592. Greater than 10,000 ohms
between stepper motor and ground
10
Circuit 593 / (BR-Y)
12 volt square wave when measured across pin
Stepper Motor driver circuit
593 and 594. Greater than 10,000 ohms
between stepper motor and ground
Stepper Motor C-910
Pin Number(s)
Circuit Designation/Description
Normal Condition/Measurement
1
Circuit 594 (BR-B)
12 volt square wave when measured across pin
593 and 594. Greater than 10,000 ohms
between stepper motor and ground.
2
Circuit 592 (W)
12 volt square wave when measured across pin
591 and 592. Greater than 10,000 ohms
between stepper motor and ground
3
Circuit 591 (BR)
12 volt square wave when measured across pin
591 and 592. Greater than 10,000 ohms
between stepper motor and ground
4
Circuit 593 (BR-Y)
12 volt square wave when measured across pin
593 and 594. Greater than 10,000 ohms
between stepper motor and ground
Primary Solenoid C-905
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