Ford Falcon. Manual — part 178

303-04b-22

Fuel Charging and Controls — Turbocharger

303-04b-22

REMOVAL AND INSTALLATION (Continued)

Installation
1. Installation is the reversal of the removal

procedure.

2. Check all connections to ensure there are no

airleaks.

G99926 en

303-04c-1 Single

Fuel

LPG 303-04c-1

SECTION : 303-04c Single Fuel LPG

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-04c-3

DESCRIPTION AND OPERATION

Single Fuel LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-04c-4

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-04c-4

Licensing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 303-04c-5

Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . .303-04c-5

Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . ..303-04c-6

Vehicle

Identification

. . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04c-7

Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-04c-8

LPG System Major Components . . . . . . . . . . . . . . . . . . . . . ..303-04c-11

Converter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04c-13

Engine Servicing Requirements . . . . . . . . . . . . . . . . . . . . . ...303-04c-16

Scheduled

Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . ...303-04c-17

DIAGNOSIS AND TESTING

Single Fuel LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-04c-20

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . ...303-04c-20

Symptom

Charts

. . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-04c-23

Connector Circuit Reference . . . . . . . . . . . . . . . . . . . . . . . 303-04c-26

REMOVAL AND INSTALLATION

Primary Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04c-29

LPG Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-04c-29

Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-04c-29

Pressure Decanting . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-04c-29

Tank Decanting . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04c-30

Tank — Ute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-04c-30

Tank — Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04c-32

Tank — Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-04c-33

Fuel Gauge and Float Assembly . . . . . . . . . . . . . . . . . . . . . . 303-04c-34

Automatic Fill Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04c-34

Service Valve (With Relief Valve on Ute and Wagon) . . . . . . . . . . . . . ...303-04c-35

Fuel Filler Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-04c-35

Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .303-04c-36

Fuel Filler Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04c-36

LPG Fuel Delivery System Hose . . . . . . . . . . . . . . . . . . . . . ...303-04c-36

Bundy Tube Connection . . . . . . . . . . . . . . . . . . . . . . . . . .303-04c-37

Converter Including Filter Lockoff & Solenoid . . . . . . . . . . . . . . . . . 303-04c-38

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-04c-39

Main/Idle/Prime Lockoff Solenoids . . . . . . . . . . . . . . . . . . . . . .303-04c-39

Converter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-04c-39

303-04c-2 Single

Fuel

LPG 303-04c-2

(Continued)

Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-04c-40

DISASSEMBLY AND ASSEMBLY

Converter with integral Filter/Lock Off

″ Solenoid . . . . . . . . . . . . . . . ..303-04c-41

Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-04c-41

Idle Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-04c-45

303-04c-3 Single

Fuel

LPG 303-04c-3

SPECIFICATIONS

General Specifications

Description

Nm

Description

Specification

Second stage section bolts (76)

4-5

Fuel Tank

Manufactured by APA

Second stage spring cap (51)

12-15

Industries

First stage lever screws (24)

1.5-2.5

Capacity

First stage cover screw (68)

1.5-2.5

Ute

92 Litres usable

Idle section bolts (76)

4-5

Sedan

93 Litres usable

Support plate screw (5)

2-2.5

Wagon

116 Litres usable

M5 cover nuts (1)

4-6

Fuel sender

40 - 250 ohms. Normal

Inlet lockoff assembly (stem) (15)

16-17

Working Range

Screw stepper motor (not shown)

4-5

Pressure relief valves

Relief Pressure - 2.55

Filter lockoff assembly (15)

22-24

on tanks

MPa

Filter bowl screws (65)

4-6

Pressure relief valve

Relief Pressure - 3.10

Idle plug (17)

3-6

(hydrostatic) on service MPa

line-

Sludge drain plugs (79)

5-7

Service line

Bundy-tube - Preformed

Balance plug (19)

10-15

5/16 " and 3/8 " diameter

with Flexible pressure

hose to the fill line.

Converter assembly

VIALLE - F5 Type

(Special)

Idle Jet

0.8mm diameter

Throttle body and mixer LPG Fuel (38mm I.D.)

assembly
Spark plugs - Iridium

K 20 SR 11

Long Life

Gap 1.1

± - 0.05mm

Torque Specifications

Description

Nm

Flared connections - All

35-38

Converted bracket to spring tower

17-23

Filler valve plate to bracket fuel tank

8-12

neck
Primary/Lock Off to Converter

10-12

Idle solenoid to converter

10-12

Converter to mounting bracket

4-8

Tank to chassis mounting bolts

80

Service valve to tank

5

AFL to tank 5Nm LPG Gauge (AXIOM) 5

to tank
Converter outlet retainer

4-8

Electrical connector bracket on

4-8 plus

converter lock offs

Loctite 262

Inlet union to converter Filter bowl

15-20

Fuel Tank Neck to Body

21-29

Converter Torque settings

Refer to

Section

310-00.

Nut (73)

1.5-2.5

Bolt water pipes (not shown)

4-5

Second stage lever screws (37)

1.5-2.5

G86720 en