Ford Falcon. Manual — part 185

303-04c-28

Single Fuel LPG

303-04c-28

DIAGNOSIS AND TESTING (Continued)

Pin Number(s)

Circuit Designation/Description

Normal Condition/Measurement

1

Circuit 1500 / (B)

0 voltage, less than 5 ohms between solenoid

Primary Solenoid ground circuit

and EEC-C Pin C21 PRIM

2

Not Used

3

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

4

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

Primary Lockoff C-907

Pin Number(s)

Circuit Designation/Description

Normal Condition/Measurement

1

Circuit 57X / (B)

0 voltage, less than 5 Ohms to chassis ground

Primary Lockoff ground circuit

2

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

Secondary Lockoff C-906

Pin Number(s)

Circuit Designation/Description

Normal Condition/Measurement

1

Circuit 57Y / (B)

0 voltage, less than 5 Ohms to chassis ground

Secondary Lockoff ground circuit

2

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

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303-04c-29

Single Fuel LPG

303-04c-29

REMOVAL AND INSTALLATION

3. Before any tank is placed into storage the liquid

Primary Service

level must be checked to ensure that the contents

is not above the maximum permitted fill level

WARNING: Where removal and installation

(80%). 110 litres for Ute, 92 litres for Sedan, 116

procedures require the handling of LPG which

litres for Wagon.

may result in the release of LPG the following

4. The tanks must be stored in the normal attitude

precautions must be taken.

i.e. as if installed in the vehicle with the supply

NOTE: Do not use a memory minder to retain

line fitting capped with pressure proof fitting.

preprogrammed data in computer controlled vehicles

NOTE: If the tank is to be removed for repair,

systems and the radio security code when the earth

returned to a test station for inspection, or the

lead is removed. Use of memory minder may lead to

tank is to be scrapped then the tank is to be

air bag deployment even though the battery is

emptied and depressurised and the interior

disconnected.

purged with inert gas.

Removal and Installation

Pressure Decanting

1. Disconnect and safely stow the vehicle’s earth

lead.

Removal and Installation

2. The working area must be registered and working 1. With the engine running, turn off the manual

procedures must comply with Australian

service valve and allow the vehicle to stall. One

Standards AS 2746.

minute after stalling, try to re-start the engine to

3. Normal precautions applicable to LPG Service

ensure complete exhaustion of fuel in the fuel

stations must be observed ie. No smoking and no

lines.

ignition sources within the working zone - ignition

2. Disconnect the vehicle battery earth lead.

off and parking brake engaged.

3. With the service valve off - disconnect the supply

line. Connect the service valve of the vehicle tank

LPG Filter

via a transfer line to the fill point of a seperate

receiving cylinder.

Removal

4. Open the ullage valve on the receiving cylinder

1. Disconnect supply connector from filter bowl.

and the service valve on the vehicle tank. When

2. Remove bowl retaining screws and lower bowl

the liquid LPG has been transferred into the

and filter from filter housing.

receiving cylinder, shut off ullage valve and the

3. Remove and discard both ‘O’ rings and filter.

service valve. Disconnect transfer line and

4. Clean out filter bowl including magnet thoroughly.

connect service valve (on the vehicle tank) to a

It is recommended that ‘O’ rings and filter be

burn off system, to burn off the remaining vapour

replaced. They are serviced as a kit.

in the vehicle tank.

Installation

WARNING: Before working on tank valves,

1. Install the ‘O’ rings into grooves - apply Shell R-10

remove any valve apart from the pressure release

oil lightly with a brush.

valve to be certain there is no residual pressure

2. Position filter with the support gauze facing up

left in the vehicle tank. To remove the valve gently

(direction of flow is from fine to coarse gauze).

loosen all screws to relieve residual pressure.

3. Carefully locate bowl and filter and install screws

Rock the valve to be sure there is no pressure.

-tighten to 4-6 Nm.

Then completely remove the valve.

Tank Assembly

WARNING: To ensure that there is no

residual LPG in the tank when the valves are

NOTE: If the tank is to be removed to enable body

removed, blow out the tank using nitrogen.

work or similar to be performed on the vehicle, it is not

necessary for the tank to be emptied. However care

WARNING: Remove pistons from solenoid

must be exercised in handling and storage of the non

coils on service valves. Open the hand taps to

emptied tank assembly. The following precautions

remove some of the residual pressure left in the

must be observed:

tanks.

Removal and Installation

CAUTION: Remove pistons from solenoid

1. Store the tanks in a well ventilated area away

coils on service valves. Open the hand taps to

from sources of ignition and drains or pits.

remove some of the residual pressure left in the

2. If two unemptied tanks are to be stored, as is the

tanks.

case of the ute, the conditions of AS1596 apply.

Before working on tank valves, remove any valve

apart from the pressure release valve to be certain

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Single Fuel LPG

303-04c-30

REMOVAL AND INSTALLATION (Continued)

there is no residual pressure left in the vehicle

Tank Decanting

tank. To remove the valve gently loosen all screws

to relieve residual pressure. Rock the valve to be

WARNING: LPG is heavier than air and any

sure there is no pressure. Then completely

depression, for example, a vehicle service pit, can

remove the valve.

be a potential reservoir for the LPG to collect.

To ensure that there is no residual LPG in the tank

when the valves are removed, blow out the tank

Removal and Installation

using nitrogen.

1. Work must be carried out in a well ventilated area,

NOTE: The receiving cylinder requires an ullage

away from any ignition source with the vehicle

valve.

battery earth disconnected. (In accordance with

Australian Standards)

NOTE: You can tell that liquid has finished

2. There are three decanting methods as follows:

transferring to the cylinder either by the contents

gauge in vehicle tank or by feeling the transfer hose.

1. Transfer pump - use in accordance with pump

instructions. (Refer note 2 below).

NOTE: The dip tube in the vehicle tank will not allow

2. Pressure decanting, refer to instruction below.

all liquid to transfer. There may be 2-3 litres remaining

in the bottom of the vehicle tank. Hence, the need to

3. Burn off method, refer to instructions below.

burn off the remainder.

Tank — Ute

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303-04c-31

Single Fuel LPG

303-04c-31

REMOVAL AND INSTALLATION (Continued)

8. Replace filler neck and tighten 3 retaining bolts to

Item

Description

10 Nm as specified.

1

Cyl Assy Fuel Tank

NOTE: If the tank had been emptied or a new

2

Screw M12x30

tank was installed, fill the tank with LPG and

check the performance of the AFL - i.e. Cuts off at

Removal

80% of tank capacity (116 litres).

1. Start

the

engine.

9. Conduct a leak test on all connections.

2. Turn the service valve "OFF".

10. Open the service valve and conduct a leak test on

3. Allow the engine to run until it stalls to use up any

all down stream connections and components.

LPG in the system.

11. Reconnect the battery earth lead.

4. Turn the ignition off.

5. Disconnect the vehicle’s battery earth lead.
6. Raise vehicle on a hoist so it can be worked

under.

7. Remove 3 bolts retaining filler assembly - slide

upwards to release tabs.

8. Disconnect sender wiring located above right

hand tank. Remove wiring from centre upper body

mount.

9. Drop

driveshaft.

10. Remove exhaust intermediate.
11. Disconnect fuel lines on left hand side under

chassis rail.

12. Disconnect left hand side ABS wiring connection

and remove clip from chassis rail.

13. Remove 5 x 12mm bolts retaining tank.
14. Carefully lower tanks to the ground using an

appropriate lifting stand.
NOTE: It is not necessary to remove the stone

shield so long as it is protected from scratching.

15. With a helper supporting the cylinder on the frame

proceed to slowly lower the cylinder ensuring the

wiring loom and LPG hoses do not get caught at

the front.

16. Once the cylinder is lower than the vehicle, move

it from beneath the vehicle.
NOTE: Empty tank mass is 60kg (approx.) so be

very careful handling it and move it to a firm base

as soon as possible.

Installation
1. Raise vehicle on a hoist so it can be worked

under.

2. Raise the tanks using an appropriate lifting stand,

aligning the 5 bolt mounting holes with the

corresponding bolt holes in the chassis.

3. Replace the 5 x 12mm bolts (2 on the chassis rail,

2 on the cross car tube) and tighten to 80 Nm as

specified.

4. Replace all wiring connectors.
5. Replace exhaust intermediate.
6. Connect and tighten fuel lines.
7. Replace drive shaft.

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