Ford Falcon. Manual — part 187

303-04c-36

Single Fuel LPG

303-04c-36

REMOVAL AND INSTALLATION (Continued)

NOTE: SEDAN & WAGON — There is a connector to

Sedan

hose on the tank assembly.

NOTE: The bundy tubing is attached to the floor pan

by pop rivets through insulated brackets and is

unlikely to ever require replacement. There is a joint,

near the base of the A pillar,which has a hydrostatic

valve attached ute only. From here, the bundy tubing

continues up and across the cowl directly to the

connector adaptor in the lower section of the filter lock

off in the engine compartment.

Fuel Delivery System - Ute

Pressure Relief Valve

This is part of the service valve on Ute and Wagon –

see service. On the Sedan it is seperate and is on the

upper valve pad.

Fuel Filler Hose

Removal
1. Disconnect the filler hose connector at AFL.
2. Disconnect the filler hose from the fuel fill valve.

Item

Description

Installation

1

Screw

1. Attach filler hose connector to fuel valve.

2

Shield

2. Check that filler hose is not squeezed between

the tank and body rail.

Fuel Delivery System - Ute

3. Connect filler hose to AFL and torque to 28-33

Nm.

LPG Fuel Delivery System Hose

WARNING: Before commencing work on the

LPG Fuel Delivery System ensure that all gas in

the lines is used up.

Start engine.
Turn off the service valve and run the engine

until it stalls.
Endeavour to re-start the engine several

times.
Disconnect the battery negative cable

Item

Description

connection.

1

Bundy tube

NOTE: UTE — The delivery of LPG from the tank to

the Filter/Lock Off is via a preformed bundy tube

2

Hydrostatic valve

which is connected to each tank and joined with a ’T’

3

Service line connectors

piece.

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303-04c-37

Single Fuel LPG

303-04c-37

REMOVAL AND INSTALLATION (Continued)

SFLPG Fuel Filler - Wagon

SFLPG Fuel Lines - Sedan

Item

Description

Item

Description

1

Tank Assy Fuel Fill

1

Screw

2

Reinf RR Floor Pan Side

2

Tube Fuel Supply

3

Screw & Washer

3

Rivet

4

Screw & Washer

Removal
Service Valve to Rear Bundy Connection

SFLPG Fuel Filler - Wagon

1. Disconnect the flexible hose at the service valve.
2. From under the vehicle disconnect the flexible

hose at the bundy connection.

3. Carefully pull the flexible hose through.
Installation
1. Install protective caps to both ends of the flexible

hose to prevent entry of foreign matter.

2. Carefully feed the flexible hose and connect to

service valve - tighten 28-33 Nm.

3. Connect the other end to the bundy tub connector

and tighten to 28-33 Nm.
NOTE: Ensure that the flexible hose is not twisted

during the tightening process.

Item

Description

Bundy Tube Connection

1

Tube Fuel Supply

2

Rivet

Removal
Filter Lock Off to Front Bundy Connection

1. Using two spanners, support the connector

adapter attached to the filter lock off lower

section.

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303-04c-38

Single Fuel LPG

303-04c-38

REMOVAL AND INSTALLATION (Continued)

2. Unscrew the service line connector at converter.

Installation
1. Reverse the above procedure ensuring that the

bundy tubing is not twisted during the tightening

process.
NOTE: When the connections at either the

service line to the filter lock off or flexible hose to

bundy tube have been completed, conduct an

LPG leak test at the connections.

Converter Including Filter Lockoff &

Solenoid

WARNING: LPG under pressure is supplied

to the converter at the filter/lock off and before

removal of the converter or filter lock off is

Item

Description

attempted the engine should be run with the

service valve turned off until it stalls. A restart

1

Connector Adapter

should be attempted to ensure that all LPG has

2

Service Line Connector

been used up. The battery earth lead should be

3

Bundy Tube

disconnected and safely stowed.

4

Filter/Lockoff

Removal and Installation

Item

Description

Item

Description

6

Coolant Inlet

1

Stepper Motor

7

Inlet Gas Lock Off Solenoid

2

Prime Solenoid

8

Liquid Gas Inlet

3

Prime Hose

9

Filter & Magnet

4

Mount Bracket

10

Drain Plugs

5

Coolant Outlet

11

Idle Solenoid

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303-04c-39

Single Fuel LPG

303-04c-39

REMOVAL AND INSTALLATION (Continued)

Item

Description

6. Disconnect converter wiring loom.

12

Balance Hose Fitting

7. Disconnect solenoid and stepper motor electrical

connectors.

13

Vapour Line Fitting

8. Remove screws retaining converter assembly

1. The converter and filter lock off assemblies are

mounting bracket to R.H. front spring tower and

bolted to mounting brackets which are in turn

lift converter from engine bay complete with

bolted to the R.H. front spring tower.

mounting bracket.

Filter

Removal
1. Disconnect supply connector from filter bowl.
2. Remove bowl retaining screws and lower bowl

and filter from filter housing.

Installation
1. Install new ’O’ rings into housing and bowl

grooves.

2. Apply Shell R10 oil to ’O’ rings with a brush.
3. Position filter into bowl with the support gauze

facing up (direction of flow is from fine to coarse

gauze).

4. Carefully locate bowl and filter and install screws

Item

Description

-tighten.

1

Converter & Bracket Assy

5. Reconnect supply connector - Tighten.

2

Bolt

Main/Idle/Prime Lockoff Solenoids

Removal
1. Disconnect electrical connector.
2. Test resistance of induction coil (12.6 Ohms at

20

°C. 12.2 Ohms at 12°C. 13.4 Ohms at 36°C ±

4%) replace if necessary.

3. Loosen coil bracket end screw.
4. Unscrew Lockoff solenoid from converter body.
Installation
NOTE: Lockoff solenoid and lockoff spindle are

serviced as an assembly.

1. Locate solenoid and lockoff spindle in position in

converter body.

Item

Description

2. Tighten. (Refer to Disassembly and Assembly

1

Nut Flanged

Section.)

2

Mounting Bracket

3. Index coil to enable easy connection of electrical

3

Retainer Clip (Fir Tree)

connector.

Installation

4. Tighten coil bracket end screw to 5 Nm.

1. Reverse removal instructions.

Converter Assembly

2. Refill cooling system of vehicle using drained

coolant if coolant is in good condition.

Removal

3. Turn on LPG service valve.

1. Turn off service valve (run engine to purge system

of LPG).

4. Check for any LPG leaks at service line

connection to filter/lock off and connections to

2. Drain vehicle cooling system into a clean

converter.

container for re-use.

5. After start up reset KAM.

3. Disconnect LPG supply line.
4. Disconnect air balance tube from the converter.
5. Disconnect vapour hose from stepper motor.

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