Ford Falcon. Manual — part 186

303-04c-32

Single Fuel LPG

303-04c-32

REMOVAL AND INSTALLATION (Continued)

Tank — Wagon

12. Remove bolts, nuts and washer assemblies

Item

Description

retaining tank. LPG wagons have two bolts that

1

Cyl Assy Fuel Tank

are accessed through holes in the rear floor.

2

Nut and Washer Asy M12

13. Carefully lower tanks to the ground using an

3

Screw M10x27

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

Removal

shield so long as it is protected from scratching.

1. Start

the

engine.

14. With a helper supporting the cylinder on the frame

2. Turn the service valve "OFF".

proceed to slowly lower the cylinder ensuring the

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

wiring loom and LPG hoses do not get caught at

LPG in the system.

the front.

4. Turn the ignition off.

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

5. Disconnect the vehicle’s battery earth lead.

it from beneath the vehicle.

6. Raise vehicle on a hoist so it can be worked

NOTE: Empty tank mass is 45kg (approx.) so be

under.

very careful handling it and move it to a firm base

as soon as possible.

7. Remove bolt retaining filler assembly.
8. Disconnect sender wiring located above front

Installation

tank.

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

9. Remove wiring from centre upper body mount.

under.

10. Remove exhaust rear.

2. Raise the tanks using an appropriate lifting stand,

aligning the 3 bolt mounting holes with the

11. Disconnect fuel lines on left hand side under

corresponding studs in the chassis.

chassis rail.

3. Replace the nuts and tighten to 80 Nm as

specified. Replace the M10x27 screws and

tighten to 55Nm.

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303-04c-33

Single Fuel LPG

303-04c-33

REMOVAL AND INSTALLATION (Continued)

4. Replace all wiring connectors.
5. Replace exhaust rear.
6. Connect and tighten fuel lines.
7. Replace filler neck and tighten retaining bolt to 10

Nm as specified.
NOTE: If the tank had been emptied or a new

tank was installed, fill the tank with LPG and

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

80% of tank capacity or 116 litres for Wagon.

8. Conduct a leak test on all connections.
9. Open the service valve and conduct a leak test on

all down stream connections and components.

10. Reconnect the battery earth lead.

Tank — Sedan

5. Disconnect the vehicle’s battery earth lead.

Item

Description

6. Raise vehicle on a hoist so it can be worked

1

Cyl Assy Fuel Tank

under.

2

Nut and Washer Asy M12

7. Remove bolt retaining filler assembly.

Removal

8. Disconnect sender wiring located above front

1. Start

the

engine.

tank.

2. Turn the service valve "OFF".

9. Remove wiring from centre upper body mount.

3. Allow the engine to run until it stalls to use up any 10. Remove exhaust rear.

LPG in the system.

11. Disconnect fuel lines on left hand side under

4. Turn the ignition off.

chassis rail.

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303-04c-34

Single Fuel LPG

303-04c-34

REMOVAL AND INSTALLATION (Continued)

12. Remove 4 nuts and washer assemblies retaining

10. Remove the gauge and float retaining screws and

tank.

lift out the gauge and float assembly.

13. Carefully lower tanks to the ground using an

Installation

appropriate lifting stand.

1. Install a new gasket under the fuel gauge and

NOTE: It is not necessary to remove the stone

carefully insert the float into the tank and locate

shield so long as it is protected from scratching.

the gauge on the tank.

2. Install the gauge retaining screws and torque to 5

14. With a helper supporting the cylinder on the frame

Nm.

proceed to slowly lower the cylinder ensuring the

wiring loom and LPG hoses do not get caught at

3. High pressure test the cylinder assemble to 2.3

the front.

MPa in accordance with clause 4.2.2 of standard

AS/NZS 1425- 1999.

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

it from beneath the vehicle.

4. Refill the tank and check the performance of the

NOTE: Empty tank mass is 45kg (approx.) so be

AFL, and gauge for correct registration.

very careful handling it and move it to a firm base 5. Connect the gauge sender wires.

as soon as possible.

6. Refit tank to vehicle as per procedure.

Installation

7. Turn the service valve on.

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

8. Close and clamp the sealed sub compartment

under.

cover.

2. Raise the tanks using an appropriate lifting stand, 9. Reconnect the battery earth lead.

aligning the 4 bolt mounting holes with the

corresponding studs in the chassis.

Automatic Fill Limiter

3. Replace the nuts and tighten to 80 Nm as

Removal

specified.

1. Start

engine.

4. Replace all wiring connectors.

2. Turn service valves off.

5. Replace exhaust rear.

3. Run the engine until it stalls.

6. Connect and tighten fuel lines.

4. Turn ignition OFF and remove battery earth lead.

7. Replace filler neck and tighten retaining bolt to 10

5. Remove tank from vehicle as per procedure.

Nm as specified.
NOTE: If the tank had been emptied or a new

6. Remove the LPG in the tank in accordance with

tank was installed, fill the tank with LPG and

the decanting procedure.

check the performance of the AFL - i.e. Cuts off at 7. Slightly loosen all AFL retaining screws to relieve

80% of tank capacity or 93 litres for Sedan.

any residual pressure.

8. Conduct a leak test on all connections.

8. Disconnect the filler hose from the AFL elbow.

9. Open the service valve and conduct a leak test on 9. Remove the elbow from the AFL.

all down stream connections and components.

10. Remove the AFL from the tank by removing the

10. Reconnect the battery earth lead.

AFL retaining screws.

Installation

Fuel Gauge and Float Assembly

1. Install a new gasket under the AFL and carefully

insert the float into the tank and locate the AFL on

Removal

the tank.

1. Start

the

engine.

2. Install the AFL retaining screws and torque to 5

2. Turn the service valve off.

Nm.

3. Run the engine until it stalls.

3. Apply Permabond A129 sealer, Locktite 577, or

4. Turn off the ignition and remove the battery earth

equivalent to the adapter elbow and install into

lead.

the AFL.

5. Remove tank from vehicle as per procedure.

4. High pressure leak test the cylinder assembly to

6. Remove the LPG in the tank in accordance with

2.3 MPa in accordance with clause 4.2.2 of

the decanting procedure.

standard AS 1425-1999.

7. Disconnect the gauge sender wires.

5. Connect the filler hose to the AFL adapter elbow.

8. Slightly loosen all gauge and float retaining

6. Refit tank to vehicle as per procedure.

screws to relieve any residual pressure in the

7. Refill the tank and check the performance of the

tank.

AFL against gauge registration.

9. Rock the gauge and float to ensure that no

8. Check for leaks.

residual pressure remains.

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303-04c-35

Single Fuel LPG

303-04c-35

REMOVAL AND INSTALLATION (Continued)

9. Turn service valve on.

2. Remove 3 bolts Ute + Wagon, (1 bolt Sedan)

fastening fuel filler bracket.

10. Reconnect the battery earth lead.

3. Remove valve assembly from body.

Service Valve (With Relief Valve on

Installation

Ute and Wagon)

1. Installation is the reverse of the removal process,

tightening 3 fastening bolts(for Ute + Wagon), 1

Removal

bolt for Sedan to 10Nm as specified.

1. Start

the

engine.

NOTE: Ensure that pipe is sealing on the Filler

2. Turn the service valve off.

Valve assembly and after installation ensure that

LPG filler gun can be applied.

3. Run the engine until it stalls.
4. Turn the ignition off and remove the battery earth

lead.

5. Remove all LPG from the cylinder in accordance

with the decanting procedure.

6. Slightly loosen the four retaining screws which

secure the service valve to the cylinder. This will

relieve any residual pressure in the cylinder.

7. Rock the service valve to ensure that no residual

pressure remains.

8. Disconnect the supply hose from the service

valve.

9. Remove the solenoid coil from the service valve

by removing the M5 bolt and sliding the coil off

the service valve.

10. Remove the service valve retaining screws and lift Tray

out the service valve and pick-up tube assembly.

Note that the pick-up tube has a fuel screen on its

lower end. Be careful not to damage this when

removing the pick-up tube assembly from the

cylinder.

Installation
1. Install a new gasket under the service valve and

carefully insert the pick-up tube and fuel screen

assembly into the cylinder. Locate the service

valve on the cylinder.

2. Install the four service valve retaining screws and

progressively torque in a cross diagonal pattern to

5 Nm.

3. Reconnect the supply hose to the service valve.
4. Refit the solenoid coil onto the service valve.

Cab Chassis

5. High pressure leak test the cylinder assembly to

2.3 MPa as per clause 4.2.2 of standard AS/NZS

1999.

6. Refill the cylinder and check the AFL performance

against the dispensing pump.

7. Turn the service valve on.
8. Reconnect battery earth lead.

Fuel Filler Valve

Removal
1. Disconnect pipe assembly connector at filler

valve. Plug pipe assembly to prevent entry of

any foreign matter.

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