Crownvic Manual

1999-2004 Ford

Dedicated CNG and Multiport

Injection Bi-Fuel CNG Vehicles

student guide

This Student Guide contains information and activities forconducting the the following courses:

3-Day Dedicated CNG and Multiport Injection Bi-Fuel CNGVehicles Course Code 41S01T0 FCS-14006-REF

2-Day Dedicated CNG Vehicles Course Code 41F01T0

2-Day Multiport Injection Bi-Fuel CNG Vehicles Course Code41F02T0

March, 2004

IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation

of all motor vehicles, as well as the personal safety of the individual doing the work. This manual

provides general directions for accomplishing service and repair work with tested, effective techniques.

Following these directions will help assure reliability.

There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well

as in the skill of the individual doing the work. This manual cannot possibly anticipate all such

variations and provide advice or cautions as to each. Accordingly, anyone who departs from

instructions provided in this manual must first establish that he/she compromises neither his/her

personal safety nor the vehicle integrity by his/her choice of methods, tools or parts.

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS.

Each one is there for a specific purpose. NOTES give you added information that will help you to

complete a particular procedure. CAUTIONS are given to prevent you from making an error that could

damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness

can cause personal injury. The following list contains some general WARNINGS that you should

follow when you work on a vehicle.

Always wear safety glasses for eye protection.

Use safety stands whenever a procedure requires you to be under the vehicle.

Be sure that the ignition switch is always in the OFF position, unless otherwise required by theprocedure.

Set the parking brake when working on the vehicle.

If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific serviceoperation.

If you have a manual transmission, it should be in NEUTRAL (engine OFF) or NEUTRAL (engine ON) WITHTHE PARKING BRAKE ON unless instructed otherwise for a specific operation.

Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.

Keep yourself and your clothing away from moving parts, such as the fan and belts, when the engine is running.

To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter, and muffler.

Do not smoke while working on the vehicle.

To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing beforebeginning to work on a vehicle. Tie long hair securely behind your head.

Keep hands and other objects clear of the radiator fan blades. Electric cooling fans can start to operateat any time by an increase in underhood temperatures, even though the ignition is in the OFF position.Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected whenworking under the hood.

The recommendations and suggestions contained in this manual are made to assist the dealer in

improving his dealership parts and/or service department operations. These recommendations and

suggestions do not supersede or override the provisions of the Warranty and Policy Manual or the

Workshop Manual.

In any cases where there may be a conflict, the provisions of the Warranty and Policy Manual or the

Workshop Manual shall govern.

The descriptions, testing procedures, and specifications in this handbook were in effect at the time the

handbook was approved for printing. Ford Motor Company reserves the right to discontinue models at any

time, or change specifications, design, or testing procedures without notice and without incurring obligation.

Any reference to brand names in this manual is intended merely as an example of the types of tools,

lubricants, materials, etc., recommended for use. Equivalents, if available, may be used. The right is reserved

to make changes at any time without notice.

Produced and Coordinated by Technical Support Operations, Ford Customer Service Division

March, 2004

i

ContentsINTRODUCTION AND PREREQUISITE REVIEW

ALTERNATIVE FUEL VEHICLE (AFV) CURRICULUM ........................................................................... Intro-2Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicle Instructor-Led Course Description ........ Intro-3Course Terminal Objectives .................................................................................................................. Intro-3Audience ................................................................................................................................................. Intro-3Course Prerequisites ............................................................................................................................. Intro-3Evaluation ............................................................................................................................................... Intro-4Student Guide ......................................................................................................................................... Intro-4SERVICE STANDARDS ........................................................................................................................... Intro-5Prerequisite Review ............................................................................................................................... Intro-6

LESSON 1: INTRODUCTION TO CNG VEHICLES

COMPRESSED NATURAL GAS (CNG) VEHICLES....................................................................................1 - 2WHAT IS NATURAL GAS? .......................................................................................................................... 1 - 3Alternative Fuel Comparison Table ........................................................................................................... 1 - 4Identification of Ford Dedicated and Bi-Fuel CNG Vehicles .................................................................... 1 - 5Changes to Base Vehicle Components on Dedicated CNG and Multiport Bi-Fuel CNG Vehicles .......1 - 6Changes to Base Vehicle Operating Strategies .......................................................................................1 - 7Supplemental Information On Alternative Fuel Vehicles ........................................................................1 - 8

LESSON 2A: DEDICATED CNG OPERATION

DEDICATED CNG VEHICLE THEORY OF OPERATION ......................................................................... 2 A - 2CNG FUEL SYSTEM PRESSURES......................................................................................................... 2 A - 6

ACTIVITY 2A — WORKSHEET A .......................................................................................................... 2 A - 10ACTIVITY 2A — WORKSHEET B .......................................................................................................... 2 A - 11ACTIVITY 2A — WORKSHEET C .......................................................................................................... 2 A - 12ACTIVITY 2A — WORKSHEET D .......................................................................................................... 2 A - 13

LESSON 2B: MULTIPORT BI-FUEL CNG VEHICLE OPERATION

MULTIPORT BI-FUEL CNG VEHICLE THEORY OF OPERATION ......................................................... 2 B - 2CNG FUEL SYSTEM PRESSURES ........................................................................................................ 2 B - 7

ACTIVITY 2B — WORKSHEET E .......................................................................................................... 2 B - 10ACTIVITY 2B — WORKSHEET F .......................................................................................................... 2 B - 11ACTIVITY 2B — WORKSHEET G.......................................................................................................... 2 B - 12ACTIVITY 2B — WORKSHEET H .......................................................................................................... 2 B - 13

LESSON 3A: DEDICATED CNG COMPONENTS

INTRODUCTION TO DEDICATED CNG COMPONENTS ......................................................................... 3A - 2CNG Fuel Fill Valve .................................................................................................................................. 3A - 3Fuel Tanks ................................................................................................................................................ 3A - 4Solenoid Tank Valve ................................................................................................................................. 3A - 5Fuel Tank Vent Box .................................................................................................................................. 3A - 7Fuel Lines................................................................................................................................................. 3A - 8Quarter-Turn Valve (1999-2003 Crown Victoria Dedicated CNG vehicles) ......................................... 3A - 10

ii

Fuel Filters ............................................................................................................................................. 3A - 11High Pressure Regulator ...................................................................................................................... 3A - 12Fuel Injection Supply Manifold ............................................................................................................. 3A - 14Fuel Injectors ......................................................................................................................................... 3A - 16

CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DEVICES..................................... 3A - 18Inputs and Outputs Chart ..................................................................................................................... 3A - 19Powertrain Control Module (PCM) ........................................................................................................ 3A - 20Unique CNG PCM Input Devices .......................................................................................................... 3A - 21Unique CNG Outputs of the PCM ......................................................................................................... 3A - 2260-Pin Alternative Fuel Control Module (AFCM) ................................................................................. 3A - 2390-Pin Alternative Fuel Control Module (AFCM) ................................................................................. 3A - 24AFCM Outputs ....................................................................................................................................... 3A - 25

ACTIVITY 3A — WORKSHEET I ............................................................................................................ 3A - 28ACTIVITY 3A - WORKSHEET J .............................................................................................................. 3A - 29ACTIVITY 3A — WORKSHEET K ........................................................................................................... 3A - 30ACTIVITY 3A — WORKSHEET L ........................................................................................................... 3A - 31

LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS

INTRODUCTION TO MULTIPORT BI-FUEL CNG VEHICLE COMPONENTS ......................................... 3B - 2CNG Fuel Fill Valve .................................................................................................................................. 3B - 3Fuel Tanks ................................................................................................................................................ 3B - 4Solenoid Tank Valve ................................................................................................................................. 3B - 5CNG Fuel Lines........................................................................................................................................ 3B - 7Coalescent Filter ..................................................................................................................................... 3B - 9High Pressure Regulator ...................................................................................................................... 3B - 10CNG Fuel Injection Supply Manifold .................................................................................................... 3B - 11Gasoline Fuel Injection Supply Manifold ............................................................................................. 3B - 12CNG and Gasoline Fuel Injectors......................................................................................................... 3B - 13CNG and Gasoline Fuel Injectors (continued) .................................................................................... 3B - 14

CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DEVICES..................................... 3B - 15Inputs and Outputs Chart ..................................................................................................................... 3B - 16Powertrain Control Module (PCM) ........................................................................................................ 3B - 17Alternative Fuel Control Module (AFCM) ............................................................................................. 3B - 18AFCM Input Devices .............................................................................................................................. 3B - 19AFCM Outputs ....................................................................................................................................... 3B - 23AFCM Outputs ....................................................................................................................................... 3B - 24AFCM Outputs ....................................................................................................................................... 3B - 25

ACTIVITY 3B — WORKSHEET M .......................................................................................................... 3B - 29ACTIVITY 3B - WORKSHEET N ............................................................................................................. 3B - 30ACTIVITY 3B — WORKSHEET O........................................................................................................... 3B - 31ACTIVITY 3B — WORKSHEET P ........................................................................................................... 3B - 32

LESSON 4: DIAGNOSIS AND SERVICE

CNG FUEL SYSTEM DIAGNOSIS AND SERVICE...................................................................................... 4 - 2SYMPTOM-TO-SYSTEM-TO-COMPONENT-TO-CAUSE (SSCC) DIAGNOSTIC STRATEGY .................... 4 - 3SERVICE AREA PRECAUTIONS ................................................................................................................4 - 5PRELIMINARY DIAGNOSTIC STEPS .........................................................................................................4 - 6IDENTIFICATION AND RETRIEVAL OF CNG SYSTEM DIAGNOSTIC TROUBLE CODES (DTCs) ..........4 - 8

iii

SERVICE PUBLICATION NAVIGATION ......................................................................................................4 - 9Powertrain Control/Emissions Diagnosis (PC/ED) Manual .....................................................................4 - 9Workshop Manual .....................................................................................................................................4 - 11Wiring Diagrams (EVTMs) .......................................................................................................................4 - 11COMPONENT AND SYSTEM TESTING AND SERVICE ..........................................................................4 - 12Cooling System Pressure Testing ...........................................................................................................4 - 13CNG REFUELING PROCEDURES ...........................................................................................................4 - 14CNG CONTAMINATION ............................................................................................................................4 - 16FUEL FILL VALVE FILTER ........................................................................................................................4 - 17COALESCENT FILTER SERVICE .............................................................................................................4 - 18FUEL INJECTOR CLEANING ...................................................................................................................4 - 19FUEL TANK REMOVAL .............................................................................................................................4 - 20FUEL LINE SERVICE ................................................................................................................................4 - 21Fuel System Leak Testing ........................................................................................................................4 - 22Crown Victoria Vent Box Leak Test .........................................................................................................4 - 24FUEL SYSTEM VENTING..........................................................................................................................4 - 25Solenoid Tank Valve Diagnostics ............................................................................................................4 - 27

DEMONSTRATION 1 - CNG VEHICLE DIAGNOSTICS ............................................................................4 - 29DEMONSTRATION 1 WORKSHEET ......................................................................................................... 4 - 30

DEMONSTRATION 2 - DEDICATED CNG OR MULTIPORT BI-FUEL CNG VENTING AND SOLENOIDDIAGNOSIS .........................................................................................................................................4 - 33

DEMONSTRATION 2 WORKSHEET .........................................................................................................4 - 34

ACTIVITY 4 — WORKSHEET Q ................................................................................................................4 - 38ACTIVITY 4 — WORKSHEET R ................................................................................................................4 - 40ACTIVITY 4 — WORKSHEET S................................................................................................................. 4 - 42ACTIVITY 4 — WORKSHEET T ................................................................................................................. 4 - 44

APPENDIX 1: COMPRESSED NATURAL GAS SAFETY

Natural Gas Vehicle Fuel System Standards ........................................................................... Appendix 1 -2Avoiding Fire or Explosion Hazards ........................................................................................ Appendix 1 -2Venting CNG Fuel ...................................................................................................................... Appendix 1 -3VISUAL INSPECTION................................................................................................................. Appendix 1 -5PAINTING A CNG VEHICLE ....................................................................................................... Appendix 1 -5Solenoid Tank Valves ................................................................................................................. Appendix 1 -6Fuel System Modifications ....................................................................................................... Appendix 1 -7Health Hazards........................................................................................................................... Appendix 1 -8

APPENDIX 2: AFV NEW GENERATION STAR TESTER OPERATION

Alternative Fuel Vehicle (AFV) DTC Retrieval ......................................................................... Appendix 2 - 2Clearing Alternative Fuel Vehicle (AFV) DTCs ........................................................................ Appendix 2 - 6NGS Parameter Identification Data (PID) Function ................................................................ Appendix 2 - 7NGS PID Viewing Options ...................................................................................................... Appendix 2 - 11

GLOSSARY ....................................................................................................... Glossary - 1TOOL LIST

ROTUNDA ORDER FORM

iv

INTRODUCTION AND PREREQUISITE REVIEW

Intro - 1March, 20041999 - 2003 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles

Introduce the Ford Alternative Fuel

Curriculum

Administer the prerequisite review

Alternative Fuel Vehicle (AFV) Curriculum

Ford 1999-2003 Dedicated CNG and MultiportBi-Fuel CNG Vehicle Instructor-Led CourseDescription

Course Terminal Objectives

Audience

Course Prerequisites

Evaluation

Student Guide

Service Standards

Prerequisite Review

CONTENTSOBJECTIVES


Intro - 2


March, 2004 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles

Courses of the Alternative Fuel Vehicle (AFV) Curriculum

The Alternative Fuel Vehicle (AFV) Curriculum consists of seven courses related to Alternative Fuel

Vehicle (AFV) diagnosis and service. With the exception of the Ford Electric Ranger Course, each

course in the curriculum is a “building block” for the next course in the curriculum.

This curriculum is designed for technicians who want to learn the methods and techniques to properly

diagnose and service AFV systems and components.

Curriculum Goals

The goals of this curriculum are as follows:

Provide the necessary training to enable technicians to “FIX IT RIGHT THE FIRST TIME, ON TIME.”

Increase technician productivity with respect to AFV diagnosis and service.

Increased customer satisfaction.

ALTERNATIVE FUEL VEHICLE (AFV) CURRICULUM

Alternative Fuel Vehicle New Generation STAR Web-Based Training - Course CodeWB31S09W0 (Optional for Ford Dealership Technicians, Mandatory for Fleet Technicians)

Alternative Fuel Handling Safety Web-Based Training - Course CodeWB 31S10W0(Mandatory for all Technicians)

Flexible Fuel Vehicle Web-Based Training - Course CodeWB 31S11W0(Mandatory for Ford Dealership Technicians, Optional for Fleet Technicians)

1999-2003 Ford Bi-Fuel CNG/LPG Vehicle (3-Day) Instructor-Led Training - CourseCode 31S13T0

Ford Electric Ranger Instructor-Led Training - Course Code 34N07T0(Optional for all Technicians)

(Mandatory for Ford Dealership Technicians, Optional for Fleet Technicians)

ALTERNATIVE FUEL VEHICLE CURRICULUM MAP

Ford Bi-Fuel CNG Vehicle (2-Day)Instructor-Led Training - Course Code31F16T0 (Fleet Technicians Only)

Ford Bi-Fuel LPG Vehicle (2-Day)Instructor-Led Training - Course Code31F17T0 (Fleet Technicians Only)

1999-2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles (3-Day) Instructor-Led Training- Course Code 41S01T0

(Mandatory for Ford Dealership Technicians, Optional for Fleet Technicians)

Ford Dedicated CNG Vehicles (2-Day)Instructor-Led Training - Course Code41F01T0 (Fleet Technicians Only)

Ford Multiport Bi-Fuel CNG Vehicles (2-Day) Instructor-Led Training - CourseCode 41F02T0 (Fleet Technicians Only)



Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles Instructor-Led CourseDescription

This is the second instructor-led course in the Alternative Fuel Vehicle Curriculum. It is a three-day

course facilitated by an instructor. This course is designed to provide hands-on opportunities for

technicians to learn and improve their skills with respect to utilizing tools and equipment and to apply

knowledge learned in previous curriculum courses.

Course Terminal Objectives

Using the information and activities provided by this course the technician will:

accurately diagnose and repair Dedicated CNG and Multiport Bi-Fuel CNG vehicle concerns using

the appropriate tools and equipment.

employ appropriate methods and techniques when servicing Dedicated CNG and Multiport Bi-Fuel

CNG vehicle systems and components.Audience

This course is designed and intended for Ford Motor Company dealership technicians who are enrolled

in the STST Alternative Fuel Vehicle Curriculum. Additionally, this course is also designed for training

service technicians of Ford Designated Fleets.

Course Prerequisites

A technician taking this course should have the following prerequisite skills, knowledge, and/or

experience:

Automotive Electrical 34S14T0

Automotive Electronics 34S19T0

Engine Performance Theory and Operation 31S07T0

Engine Performance Diagnosis and Testing 31S10T0

Additionally, technicians attending this course must have completed the following:

Alternative Fuel Vehicle New Generation STAR Web-Based Training WB 31S09W0 (Mandatory forFleet Technicians, optional for Ford Dealership Technicians).

Alternative Fuel Safety Web-Based Training WB 31S10W0 (Mandatory for all Technicians).

Flexible Fuel Vehicle Web-Based Training WB 31S11W0 (Mandatory for Ford Dealership Techni-cians).

Intro - 4



Evaluation

Hands-on skills and course related knowledge is evaluated on the afternoon of the third day.

Hands-on evaluations will be conducted with exercises in:

– Dedicated CNG and Multiport Bi-fuel CNG vehicle system diagnosis.

– Dedicated CNG and Multiport Bi-Fuel CNG vehicle system service.

– service publication CD-ROM/DVD navigation.

– special tool usage.

In order to pass the course, you must demonstrate acceptable skills at the evaluated hands-on exercises

AND you must answer at least 80% of the written post test questions correctly.

Student Guide

The Student Guide contains the worksheets used at the workstations for each of the three days. You

must complete each worksheet.

IMPORTANT: Actively participate in exercise reviews. This is your opportunity to ask questions and

clear up any areas that you may not fully understand.



Service needs courteously identified, accurately recorded on Repair Order, and verified with customer.

Standard 4

Vehicles Serviced Right on the First Visit:

Service status provided within one minute of inquiry.

Vehicle ready at agreed upon time.

Thorough explanation of work done, coverages and charges.

The technician is the most important player when it comes to Standard 4.

“Fix It Right the First Time, on Time”

Why:

Customers tell us “Fixing It Right the First Time, On Time” is one of the top reasons they would decide to

return to a dealer to buy a vehicle and get their vehicles serviced.

Technician Training

It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix It Right the First

Time, On Time.” We refer to this as “competency.”

SERVICE STANDARDS

Mission Statement

All dealership personnel will treat every customer as a potential lifetime purchaser, communicating a

professional image that embraces honesty and concern for customer wants and needs.

Dealer-to-Customer Service Standards

Appointment available within one day of the customer’s requested service day.

Write-up begins within four minutes of arrival.

Technician’s Role

The technician’s role is to acquire the skills and knowledge for competency in your specialty via:

FMT (self-study)

FORDSTAR Network (new model and curriculum)

New Model (self-study and instructor-led)

STST (instructor-led)

Web-Based Training (self-study)

Benefits

The successful implementation of standards means:

Satisfied customers

Repeat vehicle sales

Increased service department utilization

Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business”

Intro - 6



1. The vehicle and engine selection screen is necessary when using which of the following?A. Digital measurement systems.

B. Diagnostic data link.

C. New Generation STAR Setup.

D. Internal systems tests.

2. If there is an arrow at the right bottom of the menu screen it indicates which of the following?A. There are more menu selections below.

B. There are more menu selections above.

C. The NGS is in digital measurement mode.

D. The NGS is in active command mode.

3. A list of available control modules can be viewed by entering:A. diagnostic data link.

B. generic OBDII functions.

C. internal system tests.

D. special functions.

4. To retrieve DTCs you should select which of the following?A. Diag test modes.

B. Data link diagnostics.

C. View rec areas.

D. Internal systems tests.

5. A diagnostic trouble code (DTC) received during a KOEO/KOER on-demand self-test is:A. caused by a communication error.

B. caused by a network error.

C. a fault that has occurred, but may not be occurring now.

D. a fault that is occurring now.

Prerequisite Review

Introduction

This course begins with a review of the content covered in the prerequisite web-based courses. The review is

designed to help you recall the key points and basic concepts of these courses. Comprehension of these key

points and concepts is essential to being successful in this course.

Directions: Select the best answer for the questions listed on the following pages.



6. What connector is the NGS connected to on an AFV when retrieving DTCs?A. Powertrain control module (PCM) connector.

B. Data link connector (DLC).

C. Alternative fuel vehicle (AFV) module.

D. At the C4008 connector.

7. Continuous DTCs (memory codes) can be caused by:A. a fault that has occurred, but may not be occurring now.

B. a fault that is occurring now.

C. both a and b.

D. neither a nor b.

8. _______ enables you to view input signals and output commands.A. Diag test modes

B. PID data monitor & record

C. Active command mode

D. DTC library

9. The sampling rate at which the NGS can operate is directly affected by _______A. the PID priority.

B. the number of PIDs selected.

C. the number of DTCs.

D. the type of DTCs.

10. PIDs can be selected by using which of the following methods?A. Individual.

B. Groups.

C. Individual and groups.

D. Individual and blocks.

11. Once the NGS begins capturing data, the data will continue to be captured until:A. CANCEL is pressed.

B. button-7 on the numeric keypad is pressed.

C. the TRIGGER is pressed.

D. button-3 on the numeric keypad is pressed.

PREREQUISITE REVIEW (continued)

Intro - 8



13. When servicing a bi-fuel vehicle always retrieve _______ first.A. base vehicle DTCs

B. AFV DTCs

C. fuel system DTCs

D. electrical system DTCs

12. The Active command mode:A. prioritizes PIDs.

B. allows you to link with vehicle control modules.

C. tests the operation of the module communication networks.

D. tests the module’s ability to control selected outputs.

14. A vehicle with a 3000 psi fuel storage system can be refilled with which of the following?A. A 3000 psi pump.B. A 3600 psi pump.C. Either A or B.D. Neither A nor B.

15. Incorrect use of the Contour manual lockout/manual bypass may cause which of thefollowing?A. A fuel leak.B. Excess pressure.C. Poor operating conditions.D. None of the above.

16. You should never service a component on a dedicated CNG vehicle:A. when there is gasoline in the tank.B. when there is pressure in the CNG fuel lines.C. when the vehicle is in gasoline mode.D. when the compuvalve is open.

17. If a CNG vehicle is parked in the shop and natural gas is accidentally released, it wouldaccumulate in which of the following areas?A. In the vehicle.B. Near the floor.C. Near the ceiling.D. None of the above.

18. What must be done prior to servicing the CNG fuel tank on a dedicated CNG vehicle ?A. The vehicle must be switched to CNG mode.B. The vehicle must be emptied of all gasoline.C. The tank must be vented.D. All of the above.




19. If a LPG vehicle is parked in the shop and propane is accidentally released, it wouldaccumulate in which of the following areas?A. In the vehicle.B. Near the floor.C. Near the ceiling.D. None of the above.

20. If a LPG bi-fuel vehicle requires painting, and the vehicle will be placed in a paint oven, whatmust be done to the LPG tank?A. It must be covered.B. It must be vented.C. It must be removed.D. The vehicle cannot be placed in a paint oven.

21. When performing a liquid leak detection test, dishwashing soap may be used to identify leaks?A. Yes.B. No.C. On CNG vehicles only.D. On LPG vehicles only.

22. Which of the following must be performed prior to servicing a propane fueled vehicle?A. The manual shut-off valve must be opened.B. The manual shut-off valve must be closed.C. The pressure relief tank valve must be opened.D. The pressure relief tank valve must be closed.

23. Which of the following is a major difference between ethanol and gasoline?A. Gasoline is flammable.B. Ethanol is more chemically reactive.C. Ethanol is combustible.D. All of the above.

24. Which of the following must never occur when working on a FF vehicle?A. Take medication for the treatment of alcohol abuse.B. Drink ethanol.C. Inhale large quantities of ethanol.D. All of the above.

25. If fuel ethanol gets on your skin, you should:A. seek immediate medical attention.B. immediately put gloves on.C. move to fresh air.D. wash with soap and water.


Intro - 10



NOTES


1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles 1-1March, 2004


Upon completion of this lesson the student willbe able to:

– Identify the characteristics of naturalgas.

– Describe the operating characteristics ofnatural gas fueled vehicles.

– Identify the unique characteristics of fuel-ignition and combustion of natural gas.

CONTENTSOBJECTIVES

Compressed Natural Gas Vehicles

What Is Natural Gas?

Alternative Fuel Comparison Table

Identification of Ford Dedicated and Bi-Fuel CNG Vehicles

Changes to Base Vehicle Componentson Dedicated and Multiport Bi-FuelCNG Vehicles

Changes to Base Vehicle OperatingStrategies

Supplemental Information On AlternativeFuel Vehicles


1-2 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG VehiclesMarch, 2004

Ford Clean-Earth Logo

Ford Motor Company is a leader in the development and introduction of alternative fueled vehicles. For

more than two decades Ford has developed cutting edge technology to enable the effective use of

alternative fuels. The Ford commitment to maintaining a clean environment has led to the cleanest

running, most efficient, and technologically advanced alternative fueled vehicles in the world.

This training class will cover theory, operation, components, diagnosis, and service of compressed

natural gas (CNG) vehicles. The vehicles covered in this course include:

1999-2004 Crown Victoria dedicated CNG fueled vehicle

1999-2004 F-Series and E-Series dedicated CNG fueled light trucks

20031/2

& 2004 F-Series Multiport Bi-Fuel CNG fueled light trucks

COMPRESSED NATURAL GAS (CNG) VEHICLES

Cars, vans, trucks, buses, and other on-road vehicles using traditional fuels produce more than 60 percent of all

carbon monoxide (CO) pollution. They also are the second largest national source of hydrocarbons (HCs) at 29

percent and nitrogen oxides (NOx) at 31 percent, the major ingredients of unhealthful ground-level ozone. In

many urban areas, motor vehicles are the single largest source of major criteria pollutants. Motor vehicles also

emit more than 50 percent of all hazardous air pollutants.

Regardless of improvements in emissions technology, conventionally fueled motor vehicles will continue

to contribute to air pollution because the number of vehicles in use and the vehicle-miles traveled will

continue to grow.

Due to the favorable properties of natural gas as an engine fuel, Compressed Natural Gas (CNG) fueled

vehicles produce lower levels of all pollutant emissions than either conventional or reformulated gasoline

and diesel fuel.

Vehicles operating on CNG can reduce exhaust emissions of CO by approximately 70 percent, non-

methane organic gas (NMOG) by 89 percent and NOx by 87 percent. Vehicles operating on CNG can also

reduce carbon dioxide (CO2) — the principle “ greenhouse” gas — exhaust emissions by 20 - 30 percent.



According to Ford Motor Company Chairman, Bill Ford, “A good company delivers excellent products and

services; a great one does all that and strives to make the world a better place.”

Ford has been demonstrating this commitment by developing natural gas fueled vehicles for decades. Withrecent improvements in technology and the need for cleaner operating vehicles, widespread use of natural gasas a vehicle fuel makes good sense.

Compared to gasoline, natural gas fueled vehicles can reduce 85 to 90 percent emissions of carbonmonoxide and reactive hydrocarbons that contribute to smog.

Natural gas offers vehicle mileage that compares to the equivalent amount of gasoline.

When operating on natural gas, vehicle performance is similar to operation on gasoline.

Since the U.S. and Canada have the largest natural gas reserves in the world, its use as a vehicle fuel reducesdependence on imported oil.

A major advantage of natural gas is that CNG has a higher octane level than gasoline. The higher octanerating indicates that CNG burns more slowly providing smoother power strokes.

As you can see, natural gas has many advantages over other types of alternative fuels, and its use in poweringvehicles is sure to expand in the future.

WHAT IS NATURAL GAS?

Compressed Natural Gas Logo



Alternative Fuel Comparison Table

The following table compares the characteristics of Propane, Compressed Natural Gas (CNG), Methanol, and

Ethanol to Gasoline.

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knatevitaleRotderiuqerezis

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semit52.1siknaTregral



5.1siknaTregralsemit

erusserP/pmeT isp002/Tmta isp0063-0003/Tmta Pmta/Tmta Pmta/Tmta Pmta/Tmta

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Identification of Ford Dedicated and Bi-Fuel CNG Vehicles

1FTEF2595VLA00001Eighth letter “9” in VIN indicates factory-built Dedicated CNG Crown Victoria.

Typical Dedicated and Bi-Fuel CNG Vehicle Identification Number (VIN)

A “dedicated” CNG vehicle uses only CNG for fuel.

Customers that use this type of vehicle are generally those whose vehicles will be operated almostexclusively in urban areas. For these types of customers, a dedicated CNG vehicle makes sense becausethey generally fuel their vehicle at company owned facilities, or have CNG equipped fueling stationswithin their area of operation.

However, there are situations and circumstances where CNG fueling facilities are limited.

Ford, in an effort to provide its customers with maximum flexibility while reducing exhaust emissions,provides bi-fuel vehicles that can operate on either conventional gasoline or CNG.

Identification of a factory-manufactured Ford dedicated CNG and bi-fuel CNG vehicles can be made

using the vehicle identification number (VIN).

The eighth digit/letter (reading left to right) of the VIN will be a “9” for all factory-manufactureddedicated CNG Crown Victoria’s.

The eighth digit/letter (reading left to right) of the VIN will be an “M” for all factory-manufactureddedicated CNG E or F Series light trucks.

The eighth digit/letter (reading left to right) of the VIN will be a “Z” for all factory-manufactured Fordbi-fuel vehicles.

Additionally, a variety of Warning, Caution and Instruction labels are provided on the vehicle in critical

areas of the CNG and driver control systems.

1FTEF25M5VLA00001Eighth letter “M” in VIN indicates factory-built Dedicated CNG E or F-Series light truck.

1FTEF25Z5VLA00001Eighth letter “Z” in VIN indicates factory-installed bi-fuel prep vehicle.



Changes to Base Vehicle Components on Dedicated CNG and Multiport Bi-Fuel CNGVehicles

In order to ensure that vehicles that operate on CNG have the same service life and handling

characteristics of a conventional vehicle, certain changes have been made to other vehicle components.

Changes to the engine include:

Intake and exhaust valve seat inserts.

Revised and hardened intake valve seats.

Stress-relieved (flame hardened) valves.

Corrosion resistant intake valves.

Positive valve rotation during operation.

Platinum-tipped nickel-plated spark plugs (part # AGSF-22WM).

Different pistons are used in the 4.6L engine (Crown Victoria only) to increase the compression ratio.

Aluminum lower intake manifold is used on 4.6L and 5.4L engines.

Changes to the chassis include:

Upgraded suspension system to accommodate the weight of the additional fuel tanks.

Additional fuel door for the CNG fuel fill valve (Multiport Bi-Fuel CNG only).

It is important to be aware of these changes, in the event that any of these components require

replacement during vehicle service.



OBD II operating strategies have been relaxed for dedicated CNG and Multiport Bi-Fuel CNG vehicles. Thisis due to the unique operating characteristics of CNG fueled vehicles.

The following chart provides information on specific changes to CNG operating strategies.

Changes to Base Vehicle Operating Strategies

2003/2004 Crown VictoriaDedicated CNG

2003 1/2 F150 Bi-Fuel2004 1/4

Dedicated CNG E-Series

Fuel

SCP/CAN60/90 Pin

AFCM

CatMisfire

HegoEGR

Fuel

S-AirEvap

CCM

Fuel PumpIdle Speed

Purge Flow

Others

CNG Gasoline

CNG

SCP

60-Pin

Yes NoYes

Yes

Yes

Yes

N/AN/A

YesYes

YesNo

Yes

CNG/Gasoline

SCP

90-Pin

No

No

No

N/A

Yes

Yes

Yes

Yes

Yes

Yes

Yes Yes

YesYes

N/A

YesYes

Yes

YesYes

Yes

YesYes

Yes

YesNo

N/A

YesN/A

Yes

YesN/A

Yes

NoYes

CNGSCP

90-Pin

Yes = Enabled

No = Not Enabled

N/A = Not Applicable



Supplemental Information On Alternative Fuel Vehicles

There are many places where supplemental information can be obtained on AFVs. The following list provides

various organizations, phone numbers, and websites where information is available for AFVs.

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eniltoHseitiCnaelC 7348-422-008 vog.eod.seitic.www

noitartsinimdAnoitamrofnIygrenE 0088-685-202 vog.eod.aie.www

noitilaoCsaGlarutaN 2203-725-307 gro.cvgn.www

noitaicossAsaGnaciremA 0008-148-307 moc.aga.www

sserpxEGNL moc.sserpxegnI.www

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LESSON 2A: DEDICATED CNG VEHICLE OPERATION

1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles 2A-1March, 2004

LESSON 2A: DEDICATED CNG OPERATION

Upon completion of this lesson the student willbe able to:

– Identify the characteristics of natural gas.


– Identify the unique characteristics of fuelignition and combustion of natural gas.

– Explain the theory and operation ofdedicated CNG fueled vehicles.

CONTENTSOBJECTIVES

Dedicated CNG Vehicle Theory Of Operation

CNG Fuel System Pressures


2A-2 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG VehiclesMarch, 2004

DEDICATED CNG VEHICLE THEORY OF OPERATION

Typical Dedicated CNG Vehicle Components

213 4

5

6

78910

11

12

13

14 15

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4 rosneSerusserPknaTleuF 21 rotcejnIleuF

5 evlaVlliFleuF 31 liaRleuF

6 retliFtnecselaoC 41 rosneSerusserPliaRleuF

7 )noitisopnepo(evlaVnruT-retrauQ 51 rosneSerutarepmeTleuFenignE

8 rotalugeRerusserPleuF 61



DEDICATED CNG VEHICLE THEORY OF OPERATION (continued)

Dedicated CNG vehicles can be equipped with either a 4.6 liter engine (Crown Victoria) or a 5.4 liter engine (E andF-series light trucks).

The major components of a typical dedicated CNG fuel system include:

Fuel Fill Valve

Fuel Injection Supply Manifold

Fuel Tanks

Alternative Fuel Control Module (AFCM) (60 or 90-pin vehicle and MY dependent)

Fuel Pressure Regulator and Coalescent Filter Assembly

Fuel Injectors

These components combine to provide the best performance and efficiency for vehicle operation on CNG

fuel.



Typical Dedicated CNG Component Configuration (Crown Victoria Shown)

DEDICATED CNG FUEL SYSTEM THEORY AND OPERATION (continued)


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2

1

3

6

5

4

16

7

10

9

1213

14

11

15

8



The dedicated CNG fuel system on Ford vehicles operates as follows:

When the ignition switch is turned to the run or start position, the PCM energizes the fuel relay/fuel tank solenoidvalve relay (fuel pump relay).

The fuel relay/fuel tank solenoid valve relay in turn sends voltage to the solenoid tank valves, causing them to open.

The solenoid tank valves will initially only be activated for one second and then will be turned off unless the PCMreceives a PIP signal indicating that the engine is cranking.

DEDICATED CNG FUEL SYSTEM THEORY AND OPERATION (continued)

This allows high-pressure natural gas to enter the fuel lines.

The high-pressure natural gas passes through the high-pressure fuel lines, past the quarter-turn valve(Crown Victoria only) and into the high-pressure (coalescent) filter.

In the coalescent filter, water and particulate contaminates are removed from the natural gas.

Once the fuel passes through the coalescent filter, it then goes into the fuel pressure regulator.

The regulator reduces the pressure of the fuel (110-125 psi for Crown Victoria or 95-110 psi for E & F-Series) and distributes it to the fuel rails via low-pressure fuel lines, through an open low-pressure solenoidshut-off valve.

Fuel injectors located at the cylinder head inject the natural gas into the combustion chamber based on asignal sent to the injector from the PCM, via the AFCM module.

60-pin AFCM modules perform two functions:

– It acts as a relay, using the low amperage signal from the PCM to turn on the high amperage injectorcircuit.

– It translates fuel tank pressure and temperature signals into fuel level indications for the fuel gauge.

90-pin AFCM modules used on 2004 E-Series Dedicated CNG vehicles perform the following functions:

– acts as a relay, using the low amperage signal from the PCM to turn on the high amperage CNG injectorcircuit.

– translates fuel tank pressure and temperature signals into fuel level indications for the fuel gauge.

– monitors injector operation for faults.

– stores many more DTCs than the 60-pin AFCM.

The fuel injectors are pulse width modulated (PWM) to deliver a calculated amount of fuel at the intakevalve.

Since fuel pressure is constant across all engine loads, only the length of time that the injectors are opendetermines the amount of fuel injected.



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CNG fuel systems operate at very high pressures. However, these pressures will change as the fuel passes along

the fuel delivery system. The following is a description of the fuel pressures and how they change at different

points in the fuel system.

The CNG is introduced into the fuel system at the fuel fill valve. The pressure at the fill valve during fuelingwill be either 3000 psi or 3600 psi (vehicle and MY dependent).

The fuel is stored in the fuel tank at pressures as high as 3000 or 3600 psi (vehicle and MY dependent).

As the fuel moves out of the tank it remains at tank pressure as it passes through the solenoid tank valvesand into the high-pressure fuel lines.

CNG Fuel System Pressure Schematic

1

3

2

7

6

45


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The high pressure fuel lines carry the fuel at tank pressure throughout their length to the coalescent filter.

Coalescent filter pressure is the same as the tank pressure.

After leaving the coalescent filter, the fuel enters the pressure regulator.

The pressure regulator lowers the fuel pressure from tank pressure (up to 3000/3600 psi) to 110 to 125 psion Crown Victoria, or 95 to 110 psi on E & F-Series light trucks.

This lower pressure fuel moves from the pressure regulator to the fuel rails and injectors.

The fuel injectors are pulse width modulated (PWM) to deliver the fuel to the intake valve of the engine.

CNG FUEL SYSTEM PRESSURES (continued)



NOTES

ACTIVITY 2A


CONTENTSOBJECTIVES

The purpose of this activity is to:

– Reinforce the knowledge that the student

has acquired from Lessons 1 and 2.

– Allow the student to review detailed

information found in Lessons 1 and 2.

– Allow the student to locate and identify

CNG fuel system components.

Activity 2A - Worksheet A (Hands-On)

Activity 2A - Worksheet B (Hands-On)

Activity 2A - Worksheet C (Written)

Activity 2A - Worksheet D (Written)

ACTIVITY 2A

ACTIVITY 2A


ACTIVITY 2A — WORKSHEET A (Hands-On)DEDICATED CNG FUEL SYSTEM COMPONENT LOCATION

STUDENT ANSWER SHEET

Directions: Using the information in your Student Reference Guide and the service publications provided,

go to the dedicated CNG classroom vehicle and answer the following questions.

1. Locate the following components on the vehicle. These components are tagged with letters or numbers.Write the letter/number of the component next to its name on the list below.

Fuel Fill Valve

Fuel Tank Solenoid Valve

Quarter-Turn Valve

Coalescent Filter

Fuel Pressure Regulator

Fuel Rail Pressure Sensor

Engine Fuel Temperature Sensor

Fuel Injector

Low-Pressure Solenoid Shut-off Valve

High-Pressure Side Fuel Line

Low-Pressure Side Fuel Line

Alternative Fuel Control Module

Fuel Shut-off Relay

END OF WORKSHEET

ACTIVITY 2A


ACTIVITY 2A — WORKSHEET B (Hands-On)DEDICATED CNG NGS PRACTICE

STUDENT ANSWER SHEETDirections: Using the information you have learned from the NGS Web-Based Training Course, and the

NGS Appendix found at the rear of this student guide, go to the dedicated CNG classroom vehicle and

answer the following questions.

1. Connect the NGS to the classroom vehicle. What information must be programmed into the NGS before itcan be used to view PIDs?

2. Start the vehicle and allow it to idle. Use the NGS to locate the PIDs listed below from the AFCM. Note theNGS definition of the PID, and the PID values presented.

3. With the vehicle still idling, use the NGS to locate the PIDs listed below from the PCM. Note the NGSdefinition of the PID, and the PID values presented.

DIP noitinifeD eulaVdetneserP

VATFE

ILF

VPRF

VSF

FVSF

MVSF


EVIRDGAG

RPKNAT

1NSPMT

2NSPMT

ACTIVITY 2A


ACTIVITY 2A — WORKSHEET C (Written)INTRODUCTION TO CNG VEHICLES


Directions: Use the information presented in your Student Reference Guide (including the Appendix and

Glossary in the back of the guide), and from the required prerequisite courses to answer the followingquestions.

1. What type of AFV customer is likely to use dedicated CNG vehicles? ___________________________________________________________________________________________________________

PAGE#__________

2. List three reasons that natural gas is a good choice for vehicle alternative fuel.___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

PAGE#__________

3. Since natural gas is odorless and colorless in its natural state, what is added as a safety measure to helpdetect leaks? ____________________________________________________ PAGE#__________

4. If a CNG vehicle has a gas leak in a building, where will the natural gas accumulate?_________________________________________________________________________________

PAGE#__________

5. How many cubic feet of natural gas is equal to a gallon of gasoline? __________ PAGE#__________

6. What advantage does the slower combustion rate of natural gas have when used in an internalcombustion engine?__________________________________________________________________________________________________________________________________________________

PAGE#__________

7. Write the meaning of the acronyms listed below.

MYNORCA NOITINIFED

MCFA

PTF

TTF

TFE

PRF

ACTIVITY 2A


ACTIVITY 2A — WORKSHEET D (Written)DEDICATED CNG VEHICLE OPERATION



Glossary in the back of the guide), and from the required prerequisite courses to answer the following

questions.

1. On a dedicated CNG vehicle with a 60-pin AFCM, what are the two purposes of the AFCM module?__________________________________________________________________________________________________________________________________________________________________

PAGE#_______

2. On a 2003 Dedicated CNG Crown Victoria, the misfire monitor is (circle one) ENABLED or NOTENABLED or NOT APPLICABLE. PAGE#_______

3. When looking at the VIN of a Crown Victoria, how can you tell it is a factory- manufactured CNG fueledvehicle? __________________________________________________________________________

PAGE#_______

4. What method is used to increase the compression of the 4.6 liter engine in a CNG fueled Crown Victoria?_________________________________________________________________________________

PAGE#_______

5. What type of contaminates are removed from the natural gas by the coalescent filter?_________________________________________________________________________________

PAGE#_______

6. On a dedicated CNG E-series, what is the pressure of the fuel once it passes the pressure regulator?________________________________________________________________ PAGE#_______

7. On a dedicated CNG vehicle, the fuel system monitor is (circle one) ENABLED or NOT ENABLED or NOTAPPLICABLE. PAGE#_______

8. What website could be used to get information on compressed natural gas cylinder standards?_____________________________________________________________ PAGE#_______

9. Dedicated CNG vehicle fuel pressure ______________ under all engine loads.

A. increases

B. decreases

C. varies

D. is constant PAGE#_______

END OF WORKSHEET

ACTIVITY 2A


NOTES


1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles 2B-1March, 2004


Upon completion of this lesson the studentwill be able to:

– Identify the characteristics of naturalgas.


– Identify the unique characteristics offuel ignition and combustion of naturalgas.

– Explain the theory and operation ofMultiport Bi-Fuel CNG vehicles.

CONTENTSOBJECTIVES

Multiport Bi-Fuel CNG Vehicle Theory OfOperation

CNG Fuel System Pressures


2B-2 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG VehiclesMarch, 2004

MULTIPORT BI-FUEL CNG VEHICLE THEORY OF OPERATION

Typical Multiport Bi-Fuel CNG Vehicle Components

21

5

7 6

9


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8 MCFAnip-09

3

4

8

10

11

12

13

14

15

OPERATION



MULTIPORT BI-FUEL CNG VEHICLE THEORY OF OPERATION (continued)Multiport Bi-Fuel CNG vehicles are equipped with a 5.4 liter engine (F-series light trucks).

The major components of a Multiport Bi-Fuel CNG fuel system include:

Fuel Fill Valve

Gasoline Fuel Injection Supply Manifold

CNG Fuel Injection Supply Manifold

Gasoline Fuel Tank

CNG Fuel Tank

Powertrain Control Module (PCM)

90-Pin Alternative Fuel Control Module (AFCM)


Coalescent Filter Assembly

Gasoline Fuel Injectors

CNG Fuel Injectors

These components combine to provide the best performance and efficiency for vehicle operation on either

gasoline or CNG fuel.



ALT

GAS

XXXXXXXXXXXXXXXXXXXXXXXX

Multiport Bi-Fuel CNG Component Configuration

MULTIPORT BI-FUEL CNG VEHICLE THEORY OF OPERATION (continued)

1 2

7

6

5

4

3

1314

9

8

16

11

18

10

1215

19

20

17

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Multiport Bi-Fuel CNG Vehicle Operation on Gasoline

The Multiport gasoline fuel system operates as follows:

When the ignition switch is turned to the run or start position, the Alternative Fuel Control Module (AFCM)receives a signal from the ALT/GAS Switch indicating that the gasoline mode is selected.

The AFCM in turn selects operation of the gasoline fuel injectors, and checks the gasoline fuel level signalto ensure that there is enough gasoline in the fuel tank for vehicle operation.

Within milliseconds of these actions the AFCM signals the Powertrain Control Module (PCM) that thevehicle is to operate in the gasoline mode via the SCP network.

The AFCM also activates the gasoline fuel pump relay which in turn activates the gasoline fuel pump.

Upon receiving the signal indicating the type of fuel to be used, the PCM selects the operating parametersspecific to gasoline operation. It then begins sending Pulse Width Modulated (PWM) fuel injector signalsto the AFCM, which in turn acts as an injector driver and passes the signals the gasoline fuel injectors.

From this point, vehicle operation is basically the same as that of a conventional gasoline vehicle.

MULTIPORT BI-FUEL CNG VEHICLE THEORY OF OPERATION (continued)

Multiport Bi-Fuel CNG Vehicle Operation on Natural Gas

The Multiport CNG fuel system operates as follows:

When the ignition switch is turned to the run or start position, the AFCM receives a signal from the ALT/GAS switch indicating that the ALT fuel mode is selected.

The AFCM in turn selects operation of the CNG fuel injectors, and checks the CNG fuel level by monitoringfuel pressure and temperature to determine fuel density. By comparing fuel pressure and temperature withprecalibrated parameters, the AFCM determines if there is enough CNG for vehicle operation.

Within milliseconds of these actions the AFCM signals the PCM that the vehicle is to operate in the ALTfuel mode via the SCP network.

Upon receiving the signal indicating the type of fuel to be used, the PCM selects the operating parametersspecific to natural gas operation. It then begins sending PWM fuel injector signals to the AFCM, which actsas an injector driver to amplify and direct these signals to the CNG fuel injectors.

The AFCM also sends voltage to the ALT fuel relay, which in turns sends voltage to the fuel tank solenoidvalve and the fuel rail shutoff valve. This voltage opens both valves. These valves will be opened for onesecond and then will be closed unless the PCM receives a PIP signal indicating that the engine is cranking.

This allows high-pressure natural gas to enter the fuel lines.

The high-pressure natural gas passes through the high-pressure fuel lines and into the high-pressure(coalescent) filter.

In the coalescent filter, water and particulate contaminates are removed from the natural gas.



Multiport Bi-Fuel CNG Vehicle Operation on Natural Gas (continued)

Once the fuel passes through the coalescent filter it goes into the fuel pressure regulator.

The regulator reduces the pressure of the fuel to 95-110 psi and distributes it to the fuel rails via low-pressurefuel lines through the open fuel rail shutoff valve.

Fuel injectors located at the fuel rails inject the natural gas into the combustion chamber based on a signalsent to the injector from the PCM, via the AFCM module.

The 90-pin AFCM module performs the following functions:

– acts as a relay, using the low amperage signal from the PCM to turn on the high amperage CNG injectorcircuit.


– controls the gasoline fuel pump relay.

– controls the ALT fuel relay.


Since fuel pressure is constant across all engine loads, only the length of time that the injectors are opendetermines the amount of fuel injected.



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CNG FUEL SYSTEM PRESSURES

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different points in the fuel system.

The CNG is introduced into the fuel system at the fuel fill valve. The pressure at the fill valve during fuelingwill be 3600 psi.

The fuel is stored in the fuel tank at 3600 psi.

As the fuel moves out of the tank it remains at tank pressure as it passes through the solenoid tank valveand into the high-pressure fuel lines.

CNG Fuel System Pressure Schematic

1

3

2

7

6

45


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The high pressure fuel lines carry the fuel at tank pressure throughout their length to the coalescent filter.

Coalescent filter pressure is the same as the tank pressure.

After leaving the coalescent filter, the fuel enters the pressure regulator.

The pressure regulator lowers the fuel pressure from tank pressure (3600 psi) to 95 to 110 psi.

This lower pressure fuel moves from the pressure regulator to the fuel rails and injectors.

The fuel injectors are pulse width modulated (PWM) to deliver the fuel into the engine.

CNG FUEL SYSTEM PRESSURES (continued)

ACTIVITY 2B


CONTENTSOBJECTIVES


– Reinforce the knowledge that the

student has acquired from Lessons 1

and 2B.


information found in Lessons 1 and 2B.


CNG fuel system components.

Activity 2B - Worksheet E (Hands-On)

Activity 2B - Worksheet F (Hands-On)

Activity 2B - Worksheet G (Written)

Activity 2B - Worksheet H (Written)

ACTIVITY 2B

ACTIVITY 2B


ACTIVITY 2B — WORKSHEET E (Hands-On)MULTIPORT BI-FUEL CNG FUEL SYSTEM COMPONENT LOCATION


Directions: Using the information in your Student Reference Guide and the service publications provided,

go to the Bi-Fuel CNG classroom vehicle and answer the following questions.

1. Locate the following components on the vehicle. These components are tagged with letters or numbers.Write the letter/number of the component next to its name on the list below.

Fuel Fill Valve

Fuel Tank Solenoid Valve

Coalescent Filter


Regulator Coolant Line

Fuel Rail Pressure (FRP) Sensor

Fuel Rail Temperature (FRT) Sensor

CNG Fuel Injector

Gasoline Fuel Injector

Fuel Rail Shutoff Valve

High-Pressure Side Fuel Line

Low-Pressure Side Fuel Line

Alternative Fuel Control Module

Alternative Fuel Relay

Gasoline Fuel Pump Relay

END OF WORKSHEET

ACTIVITY 2B


ACTIVITY 2B — WORKSHEET F (Hands-On)MULTIPORT BI-FUEL CNG NGS PRACTICE

STUDENT ANSWER SHEETDirections: Using the information you have learned from the NGS Web-Based Training Course, and the

NGS Appendix found at the rear of this student guide, go to the Multiport Bi-Fuel classroom vehicle and

answer the following questions.

1. Connect the NGS to the classroom vehicle. What information must be programmed into the NGS before itcan be used to view PIDs? ____________________________________________________________

2. Start the vehicle and allow it to idle. Use the NGS to locate the PIDs listed below from the AFCM. Note theNGS definition of the PID, and the PID values presented.

3. With the vehicle still idling, use the NGS to locate the PIDs listed below from the PCM. Note the NGSdefinition of the PID, and the PID values presented.


NURFTLA

LEUF

WS_LES

WS_CM


11SO

PIP

MPR

EDOMPT

RWPV

LIM

END OF WORKSHEET

ACTIVITY 2B


ACTIVITY 2B — WORKSHEET G (Written)INTRODUCTION TO CNG VEHICLES



Glossary in the back of the guide), and from the required prerequisite courses to answer the followingquestions.

1. Compared with gasoline-powered vehicles, CNG fueled vehicles can reduce NOx emissions by howmuch?_______________________________________________________ PAGE#___________

2. Compared to gasoline, the octane level of CNG is (circle one) HIGHER or LOWER. PAGE#__________

3. What is usually the first indication of a natural gas leak? ____________________________________PAGE#__________

4. CNG is (circle one) LIGHTER or HEAVIER than air. PAGE#__________

5. What is the ignition point temperature of CNG? _________________________ PAGE#__________

6. What changes are made to the suspension of a bi-fuel vehicle?________________________________

_____________________________________________________________________________________________________________________________________________________________________________________________________________PAGE#__________

7. Write the meaning of the acronyms listed below.

END OF WORKSHEET

MYNORCA NOITINIFED

VFA

MCFA

EDOM_LEUF

TRF

WSLES

ACTIVITY 2B


ACTIVITY 2B — WORKSHEET H (Written)MULTIPORT BI-FUEL CNG VEHICLE OPERATION



Glossary in the back of the guide), and from the required prerequisite courses to answer the following

questions.

1. Which of the following are functions of the AFCM on an Multiport Bi-Fuel CNG Vehicle

A. Acts as a relay, using the low amperage signal from the PCM to turn on the high amperage CNG injectorcircuit.

B. Translates fuel tank pressure and temperature signals into fuel level indications for the fuel gauge.

C. Controls the gasoline fuel pump and ALT fuel relay.

D. Monitors injector operation for faults.

E. All of the above. PAGE#_______

2. On a Multiport Bi-Fuel CNG Vehicle, the fuel system monitor is (circle one) ENABLED or NOT ENABLEDor NOT APPLICABLE. PAGE#_______

3. When looking at the VIN of a Multiport Bi-Fuel CNG Vehicle, how can you tell it is a factory- manufacturedbi-fuel vehicle? ____________________________________________________________PAGE#_______

4. What is the maximum CNG pressure that can be used to refuel a Multiport Bi-Fuel CNG Vehicle?____________________________________________________________________PAGE#_______

5. What two components are controlled by the ALT fuel relay? _________________________________

_________________________________________________________________________________PAGE#_______

6. What two signals does the AFCM use to determine CNG fuel level?____________________________

_________________________________________________________________________________PAGE#_______

7. Which control module creates PWM signals to control the CNG fuel injectors? ___________________PAGE#_______

8. What is the website address for the Natural Gas Coalition? _____________________ PAGE#_______

9. Multiport Bi-Fuel CNG Vehicle fuel pressure ______________ under all engine loads.

A. increases

B. decreases

C. varies

D. is constant PAGE#_______

END OF WORKSHEET

ACTIVITY 2B


NOTES


1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles 3A - 1March, 2004

Upon completion of this lesson the student

will be able to:

– Identify advantages of dedicated CNG

vehicles.

– Explain unique CNG components.

– Describe changes to base vehicle compo-

nents on dedicated CNG vehicles.

– Explain changes to dedicated CNG vehicle

operating strategies.

Introduction To Dedicated CNG Components

CNG Fuel Fill Valve

Fuel Tanks

Solenoid Tank Valve

Fuel Tank Vent Box - Crown Victoria

Fuel Lines

Quarter-Turn Valve

Fuel Filters

High Pressure Regulator


Fuel Injectors

CNG Fuel System Control Modules And Input/Output Devices

Inputs and Outputs Chart


Unique CNG PCM Input Devices

Unique CNG Outputs of the PCM

Alternative Fuel Control Module (AFCM)

AFCM Outputs

CONTENTSOBJECTIVES



1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles3A - 2 March, 2004

INTRODUCTION TO DEDICATED CNG COMPONENTS

Dedicated CNG Vehicles

This lesson will provide information on dedicated CNG fuel system components. The vehicles covered

in this lesson include:

1999-2004 Crown Victoria with dedicated CNG fuel system.

1999-2004 E & F-Series with dedicated CNG fuel system.

Some components are only used on specific vehicles. If this is the case, the vehicle will be specified.



COMPONENT FUNCTION

Enables vehicle to receive CNG fuel.

COMPONENT LOCATION

Beneath the fuel fill door.

DESCRIPTION AND OPERATION

1999 -2004 E & F Series allows a maximum of 3600 psi of CNG to be received into the CNG fuel tanks.

1999 -2004 Crown Victoria fill valve allows 3000 psi of CNG to be received into the CNG fuel tanks(build date up to July 31, 2001). 3600 psi fill valves are installed on vehicles built after August 1, 2001.

1999 - 2000 MY has a manual back flow valve that will allow tank venting (special service toolsrequired).

Fill valves were changed over from manual backflow type to non-manual backflow type during the2001 MY.

All service replacement fill valves will be non-manual backflow type..

3600 psi fill valves will allow refueling at 3000 psi pump.

3000 psi fill valve equipped vehicles cannot be refueled at 3600 psi pumps.

This is because 3000 psi fill valves have slightly larger fittings. This fitting difference is so slight it isnot visually detectable. Refer to pressure rating stamp on fill valve fitting (P30=3000 psi valve,P36=3600 psi valve).

POSSIBLE SYMPTOMS

Valve fails to completely close after refueling causing leakage (often the result of driver failing to

replace the valve dust cover after refueling).

CNG Fuel Fill Valve

CNG Fill Valve


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Fuel Tanks

COMPONENT FUNCTION

To store pressurized CNG fuel.

COMPONENT LOCATION

F-Series – At front of truck bed near passenger compartment and beneath vehicle at midship location.

Crown Victoria – In the trunk of the vehicle and beneath the rear of vehicle.

E-Series – Behind rear axle under vehicle and in the interior passenger compartment (with optional tank).


The tank used for natural gas is designed and manufactured to meet NGV 2 requirements .

NGV 2-1 CNG tanks are made of high strength steel.

NGV 2-2 CNG tanks consist of a metal liner reinforced with resin impregnated continuous filament.

Crown Victoria tanks are rated for use at 3000 psi (build date before July 31, 2001).

E & F-Series tanks are rated at 3600 psi (1999 - 2002).

Fuel tank configurations vary between vehicle type and model year (MY). Refer to the vehicle servicepublications for information on specific vehicle and MY.

POSSIBLE SYMPTOMS

Fuel leaks caused by impact damage.

Unreadable build date tag (requires tank replacement).

Overhead View of CNG Fuel Tanks (NGV2 Type in F150)



COMPONENT FUNCTION

Prevents or allows fuel flow from the fuel tank.

COMPONENT LOCATION

Fitted into the fuel tank assembly.


The solenoid tank valve is an electrically actuated valve that prevents fuel flow from the fuel tank whenthe ignition is off.

When the ignition is turned on the solenoids receive voltage and are actuated, via the fuel pump relay.

When this occurs, fuel is allowed to flow to the other components of the fuel system.

The valve has a manual lock down feature. Refer to the service manual for specific operation of themanual lock down feature.

In the event of a stuck valve, the valve has a manual override that can be activated with manual overridetool 134-00050. However, use of the manual override damages the valve requiring it to be replaced.

Solenoid Tank Valve - F-Series

Solenoid Tank Valve

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WARNING: IF THE MANUAL OVERRIDE FEATURE MUST BE USED, THE COMPLETE

VALVE MUST BE REPLACED.

Dedicated CNG vehicles have a Pressure Relief Device (PRD) integrated into their solenoid valves.

The PRD is a metal-alloy insert that will melt if the tank is exposed to temperatures in excess of 100° C (212°F). This will allow the pressure inside the tank to be relieved, in the event that the tank is exposed to a firecondition.

DESCRIPTION AND OPERATION (continued)

Solenoid Tank Valve (continued)

POSSIBLE SYMPTOMS

Stuck open - unable to relieve pressure in fuel system during vehicle service.

Stuck closed - fuel unable to move from fuel tank into fuel system resulting in reduced range or no-startcondition.

Solenoid Tank Valve (Front and Rear Views)


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WARNING: A CNG FUEL TANK THAT SHOWS SIGNS OF FIRE DAMAGE MUST BE

REPLACED.



Fuel Tank Vent Box

COMPONENT FUNCTION:

Removes natural gas vapors from the upper tank rack assembly.

COMPONENT LOCATION:

Crown Victoria – Contained on the upper tank rack assembly.

E-Series –Will be present on any fuel tanks located inside passenger compartment.

DESCRIPTION AND OPERATION:

The fuel tank vent box is required to prevent natural gas vapors from entering the passenger compartment.

In the event of a leak, vapors would be vented below the vehicle outside the passenger and trunk compartment.

POSSIBLE SYMPTOMS

Leaks in the vent box may allow CNG vapor to escape into vehicle trunk and passenger compartment.

Dedicated E-Series Fuel Tank Vent Box


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COMPONENT LOCATION

Fuel lines run from the fill to the fuel tanks and to the other components of the CNG system.

COMPONENT FUNCTION

Carries CNG fuel from the fuel tanks to the various components of the fuel system.


Fuel lines are stainless steel with o-ring sealed fittings (CNG O-rings are identified by a yellow stripe). Theyare burst rated at 22,500 psi. and are electrically conductive.

A fuel line assembly consists of flexible hose and/or stainless steel seamless tubing, end fittings, and tube nuts.

The hose is a conductive polytetrafluoroethylene (PTFE) liner reinforced with a stainless steel wire braidedcovering.

The fittings are inserted into the hose ends and crimped into place.

The stainless steel tubing contains end fittings which are brazed to the tube.

There are high pressure fuel lines that are identified by either 1/4 inch or 3/8-inch outer diameter

Low pressure fuel lines are identified by a 1/2-inch outer diameter.

The low pressure fuel line has a quick-connect at one end for connection to the fuel rail.

The other fittings used on the natural gas vehicle to connect fuel components are SAE o-ring face seal tubefittings.

There are two end types: an o-ring face seal end and a straight thread end. On tee and elbow fittings, a washerand a positionable nut are provided to aid in orientation of the fitting.

The fuel lines meet all United States and Canadian safety specification.

Fuel Lines

Typical CNG Fuel Line

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WARNING:

NEVER USE AFTERMARKET REPLACEMENT FUEL LINES.

USE ONLY ORIGINAL EQUIPMENT REPLACEMENT LINE ASSEMBLIES.FORD FUEL LINES ARE DESIGNED TO MEET SAFETY REQUIREMENTS.

AFTERMARKET FUEL LINES OR HOSES MAY NOT COMPLY WITH THISDESIGN. FAILURE TO COMPLY COULD RESULT IN FIRE OR EXPLOSION.

POSSIBLE SYMPTOMS

Leakage due to damage or incorrect installation.

Leakage is most likely to occur in the area of fittings and connections.

Fuel Lines (continued)



Quarter-Turn Valve (1999-2003 Crown Victoria Dedicated CNG vehicles)

COMPONENT FUNCTION

Isolates the fuel tanks and solenoid tank valves from the rest of CNG fuel system.

COMPONENT LOCATION

Bottom of vehicle below passenger seat.


The quarter-turn valve isolates the fuel tanks from the rest of the fuel system. It is used during some serviceand diagnostic procedures.

When the valve handle is parallel to the fuel line the valve is open and will allow natural gas to flow to thefuel system.

When the valve handle is at a right angle to the fuel line the valve is closed, preventing natural gas flow to thefuel system.

Quarter-turn Valve (Open and Closed Position)

POSSIBLE SYMPTOMS


Incorrect valve position will prevent fuel from flowing through fuel system.


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Fuel Filters

CNG Fuel Filters

COMPONENT FUNCTION

Removes liquid and particulate contaminates from the CNG fuel system.

COMPONENT LOCATION

Particulate Filter – 1999-2001 E-Series, 1999-2004 F-Series and Crown Victoria Dedicated CNGVehicles – located at the rear of the fuel fill valve.

Coalescent Filter – Crown Victoria – immediately before the pressure regulator in front of the left rearwheel.

Coalescent Filter – E&F Series – behind the transmission crossmember.

The fill valve filter removes small particles during vehicle fueling.

The coalescent filter removes particles and moisture from the fuel before it reaches the regulator.

Both filters have regular replacement intervals, refer to maintenance chart.

The coalescent filter also has a regular draining interval to remove liquid.

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POSSIBLE SYMPTOMS

Plugged or partially plugged fuel fill valve filter may result in slow or no refueling capability.

Plugged coalescent filter element will result in no start/no run condition.

Partially plugged coalescent filter element may result in rough engine operation.




COMPONENT FUNCTION

Delivers CNG at nominal pressure for metering by fuel injectors.

COMPONENT LOCATION

Crown Victoria – immediately after coalescent filter in front of the left rear wheel.

F-Series – left-hand frame rail near transmission crossmember.

E-Series – left-hand frame rail near transmission crossmember.


CNG is delivered to the regulator at fuel system pressure.

The single-stage regulator reduces fuel pressure to a nominal 100 psi.

Engine coolant is circulated through the regulator to prevent icing that may be caused when the fuel pressureis reduced.

The regulated fuel then moves to the fuel injectors for metering and distribution.


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POSSIBLE SYMPTOMS

Possible engine coolant leak point.

Damaged o-ring may result in CNG leak.

Damaged regulator mechanism may result in a rough run/no run condition.

Regulator icing may be the result of a stuck closed thermostat.

High Pressure Regulator (continued)




COMPONENT FUNCTION:

Supplies fuel from the fuel pressure regulator to the fuel injectors.

COMPONENT LOCATION:

Top of engine.


The fuel injection supply manifold is similar to the gasoline fuel injection supply manifold. Uniquecomponents of the CNG supply manifold include:– Eight bolts mount the fuel injection supply.– Elimination of the fuel return tube.– Mounting ports for the:

• engine fuel temperature (EFT) sensor• fuel rail pressure (FRP) sensor• fuel rail shut-off solenoid

– A Schrader valve for test equipment connection (vehicle and MY dependent).

Fuel Injection Supply Manifold (Crown Victoria Shown)

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POSSIBLE SYMPTOMS

Damaged o-rings may result in CNG leak

CNG odor in engine and possibly passenger compartments.

Fuel Injection Supply Manifold (continued)



Fuel Injectors

COMPONENT FUNCTION:

Meters the fuel going into the engine combustion chambers.

COMPONENT LOCATION:

Top of engine cylinder heads.


The fuel injectors used on dedicated CNG are high-flow type (95 lb. per hr.) that were originallydesigned for use on Indy race cars.

CNG injectors can often be identified by the aqua-colored cap on the injector body, however somededicated CNG injectors installed after the 2000 model year may also be gray.

CNG injectors can always be identified by the size of the injection nozzles. It is a single large nozzle,compared to the multiple small openings that are used on gasoline injectors nozzles.

Gasoline and CNG Fuel Injectors

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POSSIBLE SYMPTOMS

Damaged o-rings may result in CNG leak.

Clogged injectors can cause a hard start/no start condition.

Engine miss/rough operation can result from individual injector malfunctions.

Fuel injector concerns can be diagnosed with the Power Balance Test to identify a suspect cylinder, then a Noidlight can be used to verify the signal from the PCM. Also an injector tester (part of special tool kit) can beapplied to diagnosis.

Fuel Injectors (continued)

The injectors are pulse width modulated (PWM) using signals sent from the PCM via the AFCM.

Because of the higher pressure and increased fuel flow requirements of CNG fuel, electrical resistanceof the injectors (4.5 ohms) is significantly lower than that of conventional gasoline injectors (14.5ohms). Because of the higher current draw of these injectors, a separate injector driver (AFCM) moduleis required.

The fuel injectors are cycled open (ON) and closed (OFF) to deliver a calculated amount of fuel at theintake valve.

Since fuel pressure is constant across all engine loads, only the length of time the injectors are opendetermines the amount of fuel injected.

Because of the high working pressure of CNG and its physical properties, CNG injectors make morenoise than gasoline injectors.




CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DEVICES

Microprocessors have not only changed the way that vehicles operate, but they have also changed the

expectations of the average consumer. Before the advent of the microprocessor, most people considered 100,000

miles to be the maximum life expectancy of the powertrain on a car or truck.

However, on modern vehicles they have come to expect a vehicle’s powertrain to last 200,000 miles and more!

How has this dramatic increase in powertrain life expectancy been accomplished? The microprocessor!

On today’s vehicles the powertrain control module (PCM) automatically adjusts the operation of the vehicle to

not only meet the operating requirements of the conditions and driver, but it also adjusts the operation to

compensate for normal component age and wear. This results in a vehicle that not only lasts longer, but also runs

better with less maintenance over its operating life.

For this reason it is essential that modern service technicians understand the operation of vehicle control

modules and how they control powertrain operation.

All control modules use input devices to monitor vehicle operating conditions. The signals received by these

devices determine the module’s operating strategy. The control module then modifies vehicle operation by

sending control signals to vehicle output devices.

The following is a description of dedicated CNG vehicle control modules and their input/output devices.




INPUTS OUTPUTS

POWERTRAIN CONTROL MODULE

(PCM)

Signals Sent Viathe J1850 Network

Injector Input SignalsSent Via HardwiredCircuits(1 circuit per injector)

Fuel PumpRelay

Engine FuelTemperature(EFT) Sensor

Fuel Rail Pressure(FRP) Sensor Fuel Rail Shutoff

Solenoid/Fuel TankSolenoidValves

Fuel TankPressure (FTP)

Sensor

Fuel TankTemperature(FTT) Sensor(upper rack)

Fuel Gauge

Low FuelIndicator Lamp

Fuel Injectors

ALTERNA-TIVEFUEL

CONTROLMODULE(AFCM)

Fuel TankTemperature(FTT) Sensor(lower rack)




COMPONENT FUNCTION:

The Powertrain Control Module (PCM) is an on-board microprocessor that controls the operation of vehiclepowertrain components.

COMPONENT LOCATION:

Varies with vehicle. Refer to EVTM for location on specific models.


The PCM on a dedicated CNG fueled vehicle operates in the same manner as on a conventional gasoline fueledvehicle.

The PCM receives input information from various sensors on the vehicle that indicate the operating conditionsof the vehicle.

The PCM then uses pre-programmed calibrations to determine what actions need to be taken to maintainoptimal vehicle operation.

The PCM then commands various devices to modify vehicle operation as required to maintain optimal vehicleoperation.

POSSIBLE SYMPTOMS

Symptoms of PCM concerns can range from no-start to incorrect operation of any PCM controlled system.





Dedicated CNG vehicles have many of the input and output devices that are normally found on a gasoline

fueled vehicle. These inputs and outputs operate in the conventional manner and perform the same functions

as they would on gasoline fueled vehicles. However, for this training course, we will focus only on those

devices that are unique to the dedicated CNG fueled vehicles.

Unique CNG Inputs to the PCM

Engine Fuel Temperature (EFT) Sensor (2-wire) (also known as the Fuel Rail Temperature (FRT)

Sensor)

The EFT sensor monitors fuel temperature in the fuel injection supply manifold.

The PCM uses the temperature indications for fuel control calculations.

Some vehicles have two temperature sensors. This will vary by model and year.

Fuel Rail Pressure (FRP) Sensor (3-wire)

Monitors the fuel pressure in the fuel rail.

This data is used by the PCM for fuel control calculations.

Unique CNG PCM Inputs

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Fuel Relay/Fuel Tank Solenoid Valve Relay

The fuel tank solenoid valve relay is identified as the FUEL PUMP RELAY on the vehicle relay cover.

When the key is in the off position, the relay is open and power to the fuel tank solenoid valves and the fuelrail shutoff solenoid is interrupted.

This isolates the fuel in the fuel tanks when the key is in the OFF position.

When the key is turned ON, the relay closes, allowing power to the fuel tank solenoid valves and the fuel railshutoff solenoid, causing them to open.

The inertia shutoff switch is also on this circuit and can cause the valves and solenoid to close in the eventof an accident.

Fuel Rail Shutoff Solenoid

The fuel rail shutoff solenoid isolates the fuel rail from the upstream fuel system when the engine is notoperating.

This minimizes the amount of fuel available to flow through the fuel injectors when the vehicle is off.

It also limits the amount of fuel that can escape through the fuel rails in the event of an accident that causesfuel rail damage.

During initial key ON, the valve will open for one second and then close again if the PCM does not detect aPIP signal that indicates the engine is being cranked or is running.


1

2

Unique CNG PCM Outputs


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COMPONENT FUNCTION:

Acts as a relay, using the low amperage signal from the PCM to turn on the high amperage injectorcircuit.

Converts signals from various inputs into a fuel level voltage signal for use by the fuel gauge.

COMPONENT LOCATION:

F-Series and Crown Victoria – On front radiator support

E-Series – Left side of engine compartment


The AFCM performs two separate functions:

– The injector driver function acts as a relay. It uses low-amperage PCM signals to control the high-amperage injector driver output required to activate the fuel injectors. This is necessary to operate the fuelinjectors at the higher operating pressures of natural gas. The AFCM performs no fuel deliverycalculations.

– Fuel level calculations are made by the AFCM based on the data received from two fuel tank racktemperature sensors (2001 MY and earlier) and the fuel tank pressure sensor. The module thenoutputs the fuel level signal as a voltage to the fuel gauge.

Typical 60-Pin Alternative Fuel Control Module (AFCM)

POSSIBLE SYMPTOMS

No-start/hard-start condition.

Rough engine operation.

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COMPONENT FUNCTION:

Acts as a relay, using the low amperage signal from the PCM to turn on the high amperage injectorcircuit.


Monitors input and output devices for correct operation and stores DTCs.

COMPONENT LOCATION:

2004 E-Series – Left side of engine compartment


The 90-Pin AFCM:

– acts as a relay, using the low amperage signal from the PCM to turn on the high amperage CNGinjector circuit.



– stores many more DTCs than the 60-pin AFCM.


POSSIBLE SYMPTOMS



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Alternative Fuel Control Module (AFCM) Inputs

Fuel Tank Pressure Sensor

Crown Victoria – The fuel tank pressure sensor is located on the upper rack assembly.

E & F-series - May be mounted on the solenoid connecting tee, which in turn mounts to the solenoidtank valve. Also may be mounted on the coalescent filter or pressure regulator (configuration is vehicleand MY dependent).

The pressure data it provides are used by the AFCM for fuel indication calculations.

Fuel Tank Temperature Sensors

Crown Victoria – there is a Fuel Tank Temperature (FTT) sensor for the tanks mounted outside thevehicle and a FTT sensor for the tanks mounted inside the vehicle .

E & F Series – Mounted on the solenoid connecting tee, which in turn mounts to the solenoid tank valve.

The sensor provides data for AFCM fuel indication calculations.

AFCM Inputs

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AFCM Outputs

Fuel Injectors

The natural gas fuel injectors are similar to gasoline injectors. However, in some ways they are unique.

– Natural gas injectors deliver a larger volume of fuel to the cylinders. This is required since CNG isa vapor and is not as energy dense as gasoline.

– The injectors have a higher noise level than gasoline injectors. This is due to the higher workingpressure of the injectors and because of the physical properties of natural gas.

– CNG injectors can be identified by their aqua color cap (MY dependent) and by their larger sizein comparison to gasoline injectors.

Fuel Gauge

The fuel gauge on a dedicated CNG fueled vehicle is similar in appearance to a fuel gauge on a gasolinefueled vehicle.

CNG fuel level indications are based on the calculations of the AFCM.

Using signals from the fuel tank pressure and fuel tank temperature sensors, the AFCM sends a voltagesignal to the fuel gauge.

The amount of voltage received determines the position of the fuel quantity needle on the face of thegauge, giving the driver a visual cue of the amount of fuel in the tanks.

Low Fuel Indicator Lamp

When the fuel level drops to between 1/8 and 1/16 of a tank the AFCM will illuminate the low fuel indicatorlamp, providing the driver a reminder of the vehicle fuel status.

AFCM Outputs

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ACTIVITY 3A


CONTENTSOBJECTIVES



student has acquired from Lessons 1,

2A, and 3A.


information found in Lessons 1,2A, and

3A.


Dedicated CNG vehicle fuel system

components.

Activity 3A - Worksheet I (Hands-On)

Activity 3A - Worksheet J (Hands-On)

Activity 3A - Worksheet K (Written)

Activity 3A - Worksheet L (Written)

ACTIVITY 3A

ACTIVITY 3A


END OF WORKSHEET

ACTIVITY 3A — WORKSHEET I (Hands-On)DEDICATED CNG FUEL SYSTEM COMPONENT IDENTIFICATION


Directions: Using the information in your Student Reference Guide and the service publications

provided, go to the dedicated CNG classroom vehicle and answer the following questions.

1. The following are descriptions of component functions. The components that perform these functions havebeen tagged by your instructor with letters/numbers. Read the function description provided then locate thecomponent that performs that function and note the letter/number and component name in the space provided.

TAG LETTER/NUMBER COMPONENT NAME COMPONENT DESCRIPTION

Removes particulate and water contamination from theCNG fuel system

Meters the fuel going into the engine combustionchambers

Sends voltage to the solenoid tank valve when the key isin the ON position

Monitors fuel temperature in the supply manifold

Carries fuel from the fuel tank to the pressure regulator

Contains a pressure relief device

Converts low-amperage signals to high-amperage signalsfor use by the fuel injectors

Provides the PCM with pressure indications for fuel controlcalculations

Provides the AFCM with pressure information

Interrupts fuel flow in the fuel rails when the engine is notoperating

May have a manual backflow feature

Converts fuel tank pressure into usable pressure for theinjectors

ACTIVITY 3A


1. In the AFCM module, select the PIDs listed in the table below for viewing. Start the vehicle and allow itto idle while viewing these PIDs. Note what data are being displayed for each PID. Refer to the servicemanual supplement and note the meaning of the data displayed.

ACTIVITY 3A - WORKSHEET JDEDICATED CNG NGS OPERATION


Directions: Using the information you have learned from the NGS Web-Based Training Course, and

the NGS Appendix found at the rear of this student guide, go to the dedicated CNG classroom vehicle

and answer the following questions..

2. Perform the following steps while viewing the PIDs listed in Question 1.

– While viewing the PIDs, raise the engine rpm to 2000 (monitor with NGS RPM PID)

– Press trigger to capture data, then allow the vehicle to run for 20 seconds.

– Save the data in area 3 of the NGS memory.

– Shut the vehicle off.

3. View the recording in the TABLE mode. What is the highest “+” time recorded on the display?______________________________________________________________________________

4. Press the RWD button. What occurs? _________________________________________________

5. Press the PLAY button. What occurs?_________________________________________________

6. Exit the TABLE mode and select the GRAPH mode. Which two PIDs are displayed?______________________________________________________________________________

7. Press the 2 button. What occurs? ____________________________________________________

8. Press the 9 button. What occurs? _____________________________________________________

9. Press the 8 button. What occurs?______________________________________________________


END OF WORKSHEET

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ACTIVITY 3A


ACTIVITY 3A — WORKSHEET K (Written)DEDICATED CNG FUEL SYSTEM COMPONENT LOCATION


Directions: Using the information you have learned from the prerequisite courses and your Student

Reference Guide, answer the following questions.

1. What is the service life of a fuel tank? ________________________________________________

PAGE#_______

2. What is a visual indication that a fuel injector is made for use with CNG?_________________________________________________________________________________________________

PAGE#_______

3. List the valves and sensors that are mounted to the fuel injection supply manifold._________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

PAGE#_______

4. In the event a solenoid tank valve is stuck closed, what should be used to vent the fuel tanks?_________________________________________________________________________________________________

What must be done if this action is performed? _________________________________________________________________________________________________

PAGE#_______

5. When the quarter-turn valve handle is at a right angle to the fuel line, the valve is (circle one) OPENOR CLOSED.PAGE#_______

6. How are the o-rings used to seal fuel lines identified? ____________________________________

PAGE#_______

7. The following is a list of inputs and outputs. In the appropriate space, note if they are an input oroutput and the control module with which they work.

END OF WORKSHEET

COMPONENT NAME INPUT OR OUTPUT CONTROL MODULE

Fuel Pump Relay

Fuel Injectors

FRP Sensor

FTP Sensor

EFT Sensor

Fuel Gauge

ACTIVITY 3A


ACTIVITY 3A — WORKSHEET L (Written)DEDICATED CNG FUEL SYSTEM COMPONENT LOCATION


Directions: Using the information you have learned and your Student Reference Guide, answer the

following questions.

1. List two base vehicle components that are changed in order to ensure that CNG vehicles have the sameservice life and handling characteristics as a conventional vehicle.___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

PAGE#_______

2. What is the physical difference between 3000 and 3600 psi. fuel fill valves?__________________________________________________________________________________________________________________________________________________________________________________________________

PAGE#_______

3. What is the burst rating of CNG fuel lines? _____________________________________________PAGE#_______

4. What two sensors are used on dedicated CNG vehicles for fuel level calculations?_________________________________________________________________________________________________PAGE#_______

5. On a E-series, what is the pressure of the CNG fuel between the fuel tank and the coalescent filter_________________________________________________________________________________________________PAGE#_______

6. On a Crown Victoria what is the pressure of the CNG fuel when it leaves the pressure regulator?_________________________________________________________________________________________________PAGE#_______

CONTINUED ON NEXT PAGE

ACTIVITY 3A


ACTIVITY 3A — WORKSHEET L (Written)DEDICATED CNG FUEL SYSTEM COMPONENT LOCATION

STUDENT ANSWER SHEET (continued)

END OF WORKSHEET

7. What is the electrical resistance of a CNG fuel injector? ___________________________________PAGE#_______

8. At what temperature will the PRD melt on a CNG solenoid tank valve? _______________________PAGE#_______

9. At what temperature will the thermostat in the pressure regulator close? ______________________PAGE#_______

10. What are the symptoms of a vent box leak on a CNG Crown Victoria?___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________PAGE#_______


1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles 3B - 1March, 2004

Upon completion of this lesson the student

will be able to:

– Identify advantages of Multiport Bi-Fuel

CNG vehicles.

– Explain unique Multiport Bi-Fuel

components.

– Describe changes to base vehicle

components on Multiport Bi-Fuel CNG

vehicles.

– Explain changes to Multiport Bi-Fuel

CNG vehicle operating strategies.

Introduction To Multiport Bi-Fuel CNGComponents

CNG Fuel Fill Valve

Fuel Tanks

Solenoid Tank Valve

Fuel Lines

Fuel Filters


Fuel Injection Supply Manifolds

Fuel Injectors

CNG Fuel System Control Modules And Input/Output Devices






AFCM Outputs

CONTENTSOBJECTIVES

LESSON 3B: MULTIPORT BI-FUEL COMPONENTS


1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles3B - 2 March, 2004

MULTIPORT BI-FUEL CNG VEHICLE COMPONENTS

Multiport Bi-Fuel CNG/Gasoline Vehicle

This lesson will provide information on the unique components and systems of Multiport Bi-Fuel CNG

vehicle components. The vehicles covered in this lesson include:

F-Series light trucks with Multiport bi-fuel CNG and gasoline fuel systems.



COMPONENT FUNCTION

Enables vehicle to receive CNG fuel.

COMPONENT LOCATION

Beneath the fuel fill door in front of the gasoline fuel fill opening of the pickup box.


3600 psi fill valves will allow refueling at both 3600 and 3000 psi pumps. This is because 3600 psi fillvalves have slightly larger fittings.

This fitting difference is so slight it is not visually detectable. Refer to pressure rating stamp on fill valvefitting.

Bi-fuel CNG fill valves have a backflow check valve that is visible at the opening.

There is also a replaceable o-ring located in the valve opening. This o-ring should be replaced accordingto the maintenance schedule .

POSSIBLE SYMPTOMS

Valve fails to completely close after refueling causing leakage (often the result of driver failing to

replace the valve dust cover after refueling).

O-ring damage may cause leakage during refueling.

CNG Fuel Fill Valve

CNG Fill Valve

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Fuel Tanks

COMPONENT FUNCTION

To store pressurized CNG fuel.

COMPONENT LOCATION

At front of truck bed near passenger compartment.


The tank used for natural gas is designed and manufactured to meet NGV 2 requirements .

NGV 2-1 CNG tanks are made of high strength steel.

NGV 2-2 CNG tanks consist of a metal liner reinforced with resin impregnated continuous filament.

Multiport Bi-Fuel CNG Vehicle CNG fuel tank is NGV2-1 and are rated at 3600 psi.

POSSIBLE SYMPTOMS

Fuel leaks caused by impact damage.

Unreadable build date tag (requires tank replacement).

Any tank exposed to open flame must be replaced.

CNG Fuel Tank (NGV2 Type 1 in Multiport F150)



COMPONENT FUNCTION

Prevents or allows fuel flow from the fuel tank.

COMPONENT LOCATION

Fitted into the fuel tank assembly.


The solenoid tank valve is an electrically actuated valve that prevents fuel flow from the fuel tank whenthe ignition is off.

When the ignition is turned on the solenoid receives voltage and are actuated (opened), via the ALT fuelrelay.

When this occurs, fuel is allowed to flow to the other components of the fuel system.

The valve has a manual lock down feature. Refer to the service manual for specific operation of themanual lock down feature.

In the event of a stuck valve, the valve has a manual override that can be activated with manual overridetool 134-00050. However, use of the manual override damages the valve requiring it to be replaced.

Solenoid Tank Valve - F-Series

Solenoid Tank Valve

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WARNING: IF THE MANUAL OVERRIDE FEATURE MUST BE USED, THE

COMPLETE VALVE MUST BE REPLACED.

Multiport Bi-Fuel CNG Vehicles have a Pressure Relief Device (PRD) integrated into their solenoidvalves.

The PRD is a metal-alloy insert that will melt if the tank is exposed to temperatures in excess of 100°C (212° F). This will allow the pressure inside the tank to be relieved, in the event that the tank isexposed to a fire condition.


Solenoid Tank Valve (continued)

POSSIBLE SYMPTOMS

Stuck open - unable to relieve pressure in fuel system during vehicle service.

Stuck closed - fuel unable to move from fuel tank into fuel system resulting in reduced range or no-startcondition.

Solenoid Tank Valve (Front and Rear Views)


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WARNING: A CNG FUEL TANK THAT SHOWS SIGNS OF FIRE DAMAGE MUST BE

REPLACED.



COMPONENT LOCATION

Fuel lines run from the fill to the fuel tanks and to the other components of the CNG system.

COMPONENT FUNCTION

Carries CNG fuel from the fuel tanks to the various components of the fuel system.


Fuel lines are stainless steel with o-ring sealed fittings (CNG O-rings are identified by a yellow stripe).They are burst rated at 22,500 psi. and are electrically conductive.

A fuel line assembly consists of flexible hose and/or stainless steel seamless tubing, end fittings, andtube nuts.

The hose is a conductive polytetrafluoroethylene (PTFE) liner reinforced with a stainless steel wirebraided covering.

The fittings are inserted into the hose ends and crimped into place.

The stainless steel tubing contains end fittings which are brazed to the tube.

There are high pressure fuel lines that are identified by either 1/4 inch or 3/8-inch outer diameter

Low pressure fuel lines are identified by a 1/2-inch outer diameter.

The low pressure fuel line has a quick-connect at one end for connection to the fuel rail.

The other fittings used on the natural gas vehicle to connect fuel components are SAE o-ring face sealtube fittings.

There are two end types: an o-ring face seal end and a straight thread end. On tee and elbow fittings,a washer and a positionable nut are provided to aid in orientation of the fitting.

The fuel lines meet all United States and Canadian safety specification.

CNG Fuel Lines

Typical CNG Fuel Lines


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WARNING:

NEVER USE AFTERMARKET REPLACEMENT FUEL LINES.

USE ONLY ORIGINAL EQUIPMENT REPLACEMENT LINE ASSEMBLIES.FORD FUEL LINES ARE DESIGNED TO MEET SAFETY REQUIREMENTS.

AFTERMARKET FUEL LINES OR HOSES MAY NOT COMPLY WITH THISDESIGN. FAILURE TO COMPLY COULD RESULT IN FIRE OR EXPLOSION.

POSSIBLE SYMPTOMS


Leakage is most likely to occur in the area of fittings and connections.

CNG Fuel Lines (continued)



Coalescent Filter

Disassembled Coalescent Filter

COMPONENT FUNCTION

Removes liquid and particulate contaminates from the CNG fuel system.

COMPONENT LOCATION

Behind the transmission crossmember.


The coalescent filter uses a paper filter element to remove particles and moisture from the fuel beforeit reaches the regulator.

The coalescent filter has a regular draining interval to remove liquid.

The paper filter element must be replaced at specified maintenance intervals, refer to the vehicle ownersmanual for specified intervals.


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POSSIBLE SYMPTOMS

Plugged coalescent filter element will result in no start/no run condition.

Partially plugged coalescent filter element may result in rough engine operation.

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COMPONENT FUNCTION

Delivers CNG at nominal pressure for metering by fuel injectors.

COMPONENT LOCATION

At right front of engine compartment


CNG is delivered to the regulator at fuel system pressure.

The single-stage regulator reduces fuel pressure to a nominal 100 psi.

Engine coolant is circulated through the regulator to prevent icing that may be caused when the fuelpressure is reduced.

The regulated fuel then moves to the fuel injectors for metering and distribution.POSSIBLE SYMPTOMS

Possible engine coolant leak point.

Damaged o-ring may result in CNG leak.

Damaged regulator mechanism may result in a rough run/no run condition.

Regulator icing may be the result of a stuck closed thermostat.


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COMPONENT FUNCTION:

Supplies fuel from the CNG fuel pressure regulator to the CNG fuel injectors.

COMPONENT LOCATION:

Top of engine.


The CNG and gasoline fuel injection supply manifolds run next to each other on top of the engine.Unique components of the CNG supply manifold include:– Eight bolts mount the fuel injection supply.– Elimination of the fuel return tube.– Mounting ports for the:

• fuel rail temperature (FRT) sensor• fuel rail pressure (FRP) sensor• fuel rail shutoff solenoid


POSSIBLE SYMPTOMS

Damaged o-rings may result in CNG leak

CNG odor in engine and possibly passenger compartments.

Damaged gasket may result in vacuum leak which would result in rough running and possible DTC.

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COMPONENT FUNCTION:

Supplies fuel from the gasoline fuel pump to the gasoline fuel injectors.

COMPONENT LOCATION:

Top of engine.


The CNG and gasoline fuel injection supply manifolds run next to each other on top of the engine.

The gasoline fuel injection supply manifold operates in the same manner as the manifold on aconventional gasoline-fueled vehicle.

POSSIBLE SYMPTOMS

Damaged o-rings may result in gasoline leak.

Damaged gasket may result in vacuum leak which would result in rough running and possible DTC.

Gasoline odor in engine and possibly passenger compartments.


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CNG and Gasoline Fuel Injectors

COMPONENT FUNCTION:

Meters the fuel going into the engine combustion chambers.

COMPONENT LOCATION:

Top of fuel injection supply manifolds (CNG injectors on CNG manifold, gasoline on gasolinemanifold).


Conventional gasoline injectors are used for gasoline delivery on Multiport Bi-Fuel CNG Vehicles.

CNG fuel injectors are high-flow type (95 lb. per hr.) that were originally designed for use on Indy racecars.

CNG injectors can often be identified by the aqua-colored cap on the injector body, however some CNGinjectors may also be gray.

Gasoline and CNG Fuel Injectors

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POSSIBLE SYMPTOMS

Damaged o-rings may result in CNG or gasoline leak.

Clogged injectors can cause a hard start/no start condition on the fuel system being used.

Engine miss/rough operation can result from individual injector malfunctions.

Fuel injector concerns can be diagnosed with the Power Balance Test to identify a suspect cylinder, thena Noid light can be used to verify the signal from the PCM. Also an injector tester (part of special toolkit) can be applied to diagnosis.

CNG and Gasoline Fuel Injectors (continued)

CNG injectors can always be identified by the size of the injection nozzles. It is a single large nozzle,compared to the multiple small openings that are used on gasoline injectors nozzles.

CNG injectors are pulse width modulated (PWM) using signals sent from the PCM via the AFCM.

Because of the higher pressure and increased fuel flow requirements of CNG fuel, electrical resistanceof the injectors (4.5 ohms) is significantly lower than that of the gasoline injectors (14.5 ohms). Becauseof the higher current draw of these injectors, a separate injector driver (AFCM) module is required.

The fuel injectors are cycled open (ON) and closed (OFF) to deliver a calculated amount of fuel at theintake valve.

Since CNG fuel pressure is constant across all engine loads, only the length of time the CNG injectorsare open determines the amount of fuel injected.

Because of the high working pressure of CNG and its physical properties, CNG injectors make morenoise than the gasoline injectors.



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Fuel Injectors (in-vehicle view)

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CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DE-VICES

Multiport Bi-Fuel CNG Vehicles have a unique control system that utilizes both the PCM and the AFCM

to meter either CNG or gasoline to the engine. These control modules depend on input devices to monitor

vehicle operating conditions. The signals received by these devices determine both module’s operating

strategies.

Based on the information received from the inputs, the PCM and AFCM work together to modify vehicle

operation by sending control signals to vehicle output devices.

The following is a description of Multiport Bi-Fuel CNG Vehicle control modules and their input/output

devices.



Inputs and Outputs ChartINPUTS OUTPUTS

POWERTRAIN CONTROL MODULE

(PCM)

Signals Sent Viathe J1850 (SCP) Network

Injector InputSignals Sent ViaHardwiredCircuits(1 circuit perinjector)

Fuel RailPressure (FRP)

Sensor

Fuel RailTemperature(FRT) Sensor

FuelSelector Light

Gasoline FuelInjectors

ALTERNA-TIVEFUEL

CONTROLMODULE(AFCM)

CNG FuelInjectors

ALT Fuel Relay

Fuel Rail ShutoffSolenoid/FuelTank Solenoid

Valve

ALT/GAS Switch

Gasoline FuelPump Relay

Gasoline FuelLevel Signal

PCM

PCM

Fuel TankPressure (FTP)

Sensor

AFCM

VSS

IAT

EGR MIL

Spark Advance

AFCM

HEC Module

Fuel Gauge(CNG orgasoline)

Low FuelIndicator Light




COMPONENT FUNCTION:

The Powertrain Control Module (PCM) is an on-board microprocessor that controls the operation of vehiclepowertrain components.

COMPONENT LOCATION:

Lower right hand side of engine compartment in bulkhead.


The PCM on a Multiport Bi-Fuel CNG Vehicle utilizes two different sets of preprogrammed strategies.Each strategy is specific to the type of fuel upon which the vehicle is operating. The AFCM tells the PCMwhich type of fuel is to be used (based on the signal from the ALT/GAS Switch , then the PCM selectsthe correct strategy to be used.

The PCM receives input information from various sensors on the vehicle that indicate the operatingconditions of the vehicle.

The PCM then uses the appropriate preprogrammed calibrations to determine what actions need to betaken to maintain optimal vehicle operation for the type of fuel being used.

The PCM then commands various devices to modify vehicle operation as required to maintain optimalvehicle operation.

The PCM is both and input to and output of the Alternative Fuel Control Module (AFCM).

POSSIBLE SYMPTOMS

Symptoms of PCM concerns can range from no-start to incorrect operation of any PCM controlled system.





COMPONENT FUNCTION:

Acts as a relay, using the low amperage signal from the PCM to turn on the high amperage CNG injectorcircuit.


Provides diagnostic capability for the CNG fuel system in the form of Diagnostic Trouble Codes (DTCs)and PID readings.

COMPONENT LOCATION:

On front radiator support


The AFCM acts as a relay for CNG injector operation. It uses low-amperage PCM signals to control thehigh-amperage injector driver output required to activate the fuel injectors. This is necessary to operatethe fuel injectors at the higher operating pressures of natural gas.

During gasoline operations the AFCM turns on the fuel pump and utilizes a set of gasoline injectordrivers to control the gasoline fuel injectors as commanded by the PCM.

The AFCM performs no fuel delivery calculations.

Fuel level calculations are made by the AFCM based on the data received from the fuel tank pressuresensor. The module then outputs the fuel level signal to the Hybrid Electronic Control (HEC) module,which in turn sends signals to the fuel gauge.

The AFCM will store DTCs relating to its operation. Additionally, it enables a scan tool to monitor theoperation of its inputs and outputs using the scan tool PID function.

Multiport Alternative Fuel Control Module (AFCM)

POSSIBLE SYMPTOMS



1



AFCM Input Devices

Inputs to the AFCM

Fuel Rail Temperature (FRT) Sensor (2-wire)

The FRT sensor monitors CNG fuel temperature in the CNG fuel injection supply manifold.

The PCM uses the temperature indications for fuel control calculations.

The AFCM uses the temperature indications for fuel level calculations.

FRT signals are sent to the PCM from the AFCM via the SCP network.

Fuel Rail Pressure (FRP) Sensor (3-wire)

Monitors the fuel pressure in the CNG fuel injection supply manifold.

This data is used by the PCM for fuel control calculations.

FRP signals are sent to the PCM from the AFCM via the SCP network.

FRT and FRP

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AFCM Input Devices (continued)

Fuel Tank Pressure (FTP) Sensor

May be mounted in one of several locations - It may be mounted on the solenoid connecting tee, whichin turn mounts to the solenoid tank valve. Also may be mounted on the coalescent filter or pressureregulator (configuration is vehicle and MY dependent).

The pressure data it provides are used by the AFCM for fuel indication calculations.

Fuel Tank Pressure (FTP) Sensor


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All bi-fuel vehicles have a ALT/GAS Switch mounted on the instrument panel that allows the driver to

select whether the vehicle runs on CNG or gasoline.

Note:

• CNG bi-fuel vehicles default to gasoline operating mode at or below 13° F.

• CNG bi-fuel vehicles will switch over to gasoline operating mode if fuel rail pressure drops below 75psi.

• The PCM determines which type of fuel to use based on engine coolant temperature (ECT) or cylinderhead temperature (CHT) sensor signals.

COMPONENT FUNCTION

• Switch allows the driver to select either CNG or gasoline operating mode.

• The fuel selector light indicates if the vehicle is operating in the CNG or gasoline mode.

• Notifies the driver if a communication or emissions critical fault has occurred.

• These functions make the switch and light both an input and output.

COMPONENT LOCATION

• Instrument panel left of the steering wheel.


• The ALT/GAS Switch is a single pole double throw (SPDT) switch with a self-contained green LEDlight.


ALT/GAS Switch

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• The switch is supplied with battery voltage through the AFCM and returns voltage on either the ALT(CNG) or GAS (gasoline) selector line.

If battery voltage is not returned on the ALT/FUEL line, the system defaults to gasoline mode.

When illuminated, the switch LED indicates that the vehicle is being operated in the CNG mode.

The switch LED is controlled by the AFCM, not the position of the switch. This means that even if theswitch is in the ALT position, the LED will not illuminate unless the vehicle is actually operating onCNG. Remember, the CNG operating mode is dependent on ECT sensor temperature readings.

Bi-fuel vehicles must be started with the ALT/GAS Switch in the mode (either ALT or GAS) desired.Changing the position of the ALT/GAS Switch after the vehicle is running will not cause the vehicle tochange the fuel being used. In order to change the fuel being used, the ignition must be placed in theOFF position, then the position of the ALT/GAS Switch is changed, then the vehicle can be started usingthe desired fuel.

SYMPTOMS

If an emissions critical fault occurs in the CNG system the AFCM will flash the fuel indicator light andthe PCM will illuminate the malfunction indicator light (MIL) to notify the driver of the condition.





AFCM Outputs

Fuel Injectors

The AFCM determines weather the gasoline or CNG injectors are to be used based upon inputinformation. It then acts as the injector driver for the type of injectors selected.

For more details refer to the fuel injector operation section found earlier in this lesson.

Fuel Gauge

The fuel gauge on a Multiport bi- fuel vehicle is similar in appearance to a fuel gauge on a gasoline fueledvehicle.

CNG fuel level indications are based on the calculations of the AFCM.

In the gasoline mode, the AFCM receives the gasoline fuel gauge signal via the SCP network. It thensends this signal to the Hybrid Electronic Control (HEC) module which in turn controls the fuel gauge.

In the CNG mode, the AFCM sends a pulse width modulated signal to the HEC module to indicate thelevel of CNG in the fuel tanks.

The signal is based on fuel density which the AFCM interprets from the fuel tank pressure (FTP) sensorand fuel rail temperature (FRT) sensor signals.

The HEC module in turn sends a signal to the fuel gauge which controls the position of the fuel quantityneedle, giving the driver a visual cue of the amount of fuel in the tanks.

Low Fuel Indicator Lamp

When the fuel level drops to between 1/8 and 1/16 of a tank the AFCM will illuminate the low fuelindicator lamp via the HEC module, providing the driver a reminder of the vehicle fuel status.

AFCM Outputs

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ALT Fuel Relay

When the key is in the off position, the relay is open and power to the fuel tank solenoid valve and thefuel rail shutoff valve is interrupted.

This isolates the fuel in the fuel tanks when the key is in the OFF position.

When the key is turned ON, the AFCM closes the relay, allowing power to the fuel tank solenoid valveand the fuel rail shutoff valve, causing them to open.

During initial key ON, the relay will close for one second and then open again if the PCM does not detecta PIP signal that indicates the engine is being cranked or is running.

The inertia shutoff switch is also on this circuit and can cause the valves to close in the event of anaccident.

Fuel Pump Relay

The AFCM uses the fuel pump relay to turn the gasoline fuel pump on when gasoline fuel is to be used

When the key is turned ON, the AFCM closes the relay, allowing power to the gasoline fuel pump,turning it on.

The inertia shutoff switch is also on this circuit and can shut the fuel pump off in the event of an accident.

During initial key ON, the relay will close for one second and then open again if the PCM does not detecta PIP signal that indicates the engine is being cranked or is running.

AFCM Outputs

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2

Multiport Bi-Fuel System Relays


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Fuel Rail Shutoff Solenoid

The fuel rail shutoff solenoid isolates the fuel rail from the upstream fuel system when the engine is notoperating.

This minimizes the amount of fuel available to flow through the fuel injectors when the vehicle is off.

It also limits the amount of fuel that can escape through the fuel rails in the event of an accident thatcauses fuel rail damage.

During initial key ON, the valve will open for one second and then close again if the PCM does not detecta PIP signal that indicates the engine is being cranked or is running.

ALT/GAS Switch Indicator Light:

The ALT/GAS Switch indicator light is a 12 volt LED, incorporated into the switch and powered whenthe vehicle is running on CNG.

It is controlled by the AFCM, not the position of the switch.

For more details refer to the ALT/GAS Switch operation section found earlier in this lesson.

AFCM Outputs

Fuel Rail Shutoff Solenoid and ALT/GAS Switch Light


1 rotacidnIhctiwSSAG/TLA 2 dioneloSffotuhSliaRleuF

12



NOTES

ACTIVITY 3B

3B - 271999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles March, 2004

CONTENTSOBJECTIVES



student has acquired from Lessons 1,

2B, and 3B.


information found in Lessons 1, 2B,

and 3B.

– Allow the student to identify the loca-

tion, function, and operation of

Multiport Bi-Fuel CNG Vehicle compo-

nents.

Activity 3B - Worksheet L (Hands-On)

Activity 3B - Worksheet M (Hands-On)

Activity 3B - Worksheet N (Written)

Activity 3B - Worksheet O (Written)

ACTIVITY 3B

ACTIVITY 3B

3B - 28 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG VehiclesMarch, 2004

NOTES

ACTIVITY 3B


END OF WORKSHEET

ACTIVITY 3B — WORKSHEET M (Hands-On)MULTIPORT BI-FUEL SYSTEM COMPONENT IDENTIFICATION


Directions: Using the information in your Student Reference Guide and the service publications

provided, go to the dedicated CNG classroom vehicle and answer the following questions.

1. The following are descriptions of component functions. The components that perform these functions havebeen tagged by your instructor with letters/numbers. Read the function description provided then locate thecomponent that performs that function and note the letter/number and component name in the space provided.

TAG LETTER/NUMBER COMPONENT NAME COMPONENT DESCRIPTION

Stores fuel at a maximum of 3600 psi

Meters CNG fuel going into the engine combustionchambers

Sends voltage to the solenoid tank valve and the fuel railshutoff valve when the key is in the ON position

Enables the driver to select either CNG or gasoline

Is shut off by the AFCM during CNG operation

Contains a pressure relief device

Stores fuel injector DTCs

Provides the AFCM with temperature indications for fuellevel calculations

Provides the AFCM with pressure information

Interrupts fuel flow in the fuel rails when the engine is notoperating

Allows the AFCM to control gasoline fuel pump operation

Converts fuel tank pressure into usable pressure for theinjectors

ACTIVITY 3B


1. In the AFCM module, select the PIDs listed in the table below for viewing. Start the vehicle and allow itto idle while viewing these PIDs. Note what data are being displayed for each PID. Refer to theservice publications and note the meaning of the data displayed.

ACTIVITY 3B - WORKSHEET NMULTIPORT BI-FUEL NGS OPERATION


Directions: Using the information you have learned from the NGS Web-Based Training Course, and

the NGS Appendix found at the rear of this student guide, go to the dedicated CNG classroom vehicle

and answer the following questions..

2. Perform the following steps while viewing the PIDs listed in Question 1.

– While viewing the PIDs, raise the engine rpm to 2000 (monitor with NGS RPM PID)

– Press trigger to capture data, then allow the vehicle to run for 20 seconds.

– Save the data in area 3 of the NGS memory.

– Shut the vehicle off.

3. View the recording in the TABLE mode. What is the highest “+” time recorded on the display? __________________________________________________________________________________

4. Press the RWD button. What occurs? __________________________________________________

5. Press the PLAY button. What occurs? ___________________________________________________

6. Exit the TABLE mode and select the GRAPH mode. Which two PIDs are displayed?______________________________________________________________________________





END OF WORKSHEET

DIP DEYALPSIDATAD ELDITAGNIDAER

LOSFFOSTLA

RPKNATGNC

BAERPRF

BAPMTRF

ACTIVITY 3B


ACTIVITY 3B — WORKSHEET O (Written)MULTIPORT BI-FUEL SYSTEM COMPONENT DESCRIPTION AND OPERATION


Directions: Using the information you have learned from the prerequisite courses and your Student

Reference Guide, answer the following questions.

1. The CNG fuel fill valve on a Multiport Bi-Fuel CNG Vehicle is stamped with 3600. What does thisindicate?______________________________________________________________________________

PAGE#_______

2. What type of fuel injector has a single large orifice in the nozzle? ___________________________PAGE#_______

3. Which part of the coalescent filter should be replaced during scheduled maintenance? _________________________________________________________________________________________

PAGE#_______

4. In the event a solenoid tank valve is stuck closed, what should be used to vent the fuel tanks? ___________________________________________________________________________________

What must be done if this action is performed? ____________________________________________PAGE#_______

5. What is the typical resistance of a CNG fuel injector? _____________________PAGE#_______

6. Which control module performs fuel delivery calculations? ________________ PAGE#_______

7. What two relays allow the AFCM to control fuel delivery to both the CNG and gasoline fuel systems?________________________________________________________________________________

PAGE#_______

8. What is the function of the FRT sensor?__________________________________________________________________________________________________________________________________________________

PAGE#_______

9. How are FRP sensor signals sent to the PCM? __________________________________________________________________________________________________________________________________________

PAGE#_______

10. Which control module uses FTP sensor signals for fuel level calculations? ____________________PAGE#_______

11. During cold weather, which temperature sensor(s) provides the PCM with readings that it uses todetermine if the vehicle should default to gasoline operation? ______________________________

PAGE#_______

12. If a Multiport bi-fuel vehicALT/GAS Switch is placed in the ALT position, but there is no CNG fuel inthe fuel tank, the fuel indicator light will be (Circle one) ON or OFF PAGE#_______

END OF WORKSHEET

ACTIVITY 3B


ACTIVITY 3B — WORKSHEET P (Written)MULTIPORT BI-FUEL SYSTEM COMPONENT DESCRIPTION AND OPERATION


Directions: Using the information you have learned and your Student Reference Guide, answer the


1. What system is modified in order to accommodate the weight of additional fuel tanks on a MultiportBi-Fuel CNG Vehicle?____________________________________________________________PAGE#_______

2. If an emissions critical fault is detected by the AFCM, what action will it take to alert the driver tothe condition? __________________________________________________________PAGE#_______

3. What will occur if the driver changes the position of the ALT/GAS Switch while driving? __________________________________________________________________PAGE#_______

4. Which control module sends a signal to the fuel gauge to change the position of the fuel quantityneedle?__________________________________________________________________PAGE#_______

5. On a Multiport Bi-Fuel CNG Vehicle, what is the pressure of the CNG fuel between the coalescentfilter and the pressureregulator?_______________________________________________PAGE#_______

6. On a Multiport Bi-Fuel CNG Vehicle, what is the pressure of the CNG fuel when it leaves thepressure regulator?__________________________________________________________________PAGE#_______

7. What safety device is in wired into both the CNG and gasoline fuel systems?__________________________________________________________________PAGE#_______

8. While testing the voltage on the ALT fuel relay circuit, after KOEO the voltage from the relay to thefuel rail shutoff valve goes from battery voltage to 0 after 1 second. Technician A says that thisindicates the ALT fuel relay is opening. Technician B says that this is normal operation. Who isright?

A. Technician A

B. Technician B

C. Both A and B

D. Neither A nor B PAGE#_______

9. What is the outer diameter of low pressure CNG fuel lines? ___________________PAGE#_______

10. During a visual inspection of a Multiport Bi-Fuel CNG Vehicle fuel tank it is noted that the tankbuild date cannot be read. Technician A says that the build date can be checked using the vehicleVIN, and a new build date sticker must be attached to the tank. Technician B says that since thetank is made of high strength steel it is an NGV 2-2 type tank. Who is right?

A. Technician A

B. Technician B

C. Both A and B

D. Neither A nor B

PAGE#_______END OF WORKSHEET


1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles 4- 1March, 2004


Upon completion of this lesson the student will be able to:

– Identify Ford service standards.

– Explain the Ford diagnostic strategy.

– Describe preliminary diagnostic steps.

– Identify CNG component tests.

– Describe dedicated CNG fueling procedures.

– Explain common dedicated CNG vehicle service procedures.

– Perform service publication navigation.

– Perform CNG fuel ventingprocedures.

Introduction

Service Standards

Preliminary Diagnostic Steps

Identification and Retrieval of CNG System

Diagnostic Trouble Codes

Diagnostic Strategy

Component and System Testing and Service

Coolant System Pressure Testing

Fueling Dedicated CNG Vehicles

CNG Contamination

Fuel Fill Valve Filter

Coalescent Filter Service

Fuel Injector Cleaning

Fuel Tank Removal

Fuel Line Service

Fuel System Leak Testing

Crown Victoria Vent Box Leak Testing

Fuel System Venting

Solenoid Tank Valve Diagnostics

OBJECTIVES CONTENTS

4 - 1


4 - 2 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG VehiclesMarch, 2004

CNG FUEL SYSTEM DIAGNOSIS AND SERVICE

When diagnosing a vehicle concern, most experienced automotive technicians follow a standard

procedure. They do this automatically, sometimes without even being aware of it, because their years

of experience have taught them that by following a standard procedure they are less likely to miss a

small, easy-to-fix item that may be responsible for a malfunction. Few things are more aggravating than

replacing an expensive, hard-to-service component, only to find out that it did not correct the concern.

Then, upon further investigation, finding out that the real cause was a broken wire that would have

been seen had a thorough visual inspection been performed.

This lesson will focus on using systematic diagnostic procedures for identifying and correcting

Dedicated CNG vehicle and Multiport Bi-Fuel CNG Vehicle concerns.



SYMPTOM-TO-SYSTEM-TO-COMPONENT-TO-CAUSE (SSCC)DIAGNOSTIC STRATEGY

After studying the methods of many successful technicians, Ford has developed a diagnostic strategy

that will help you to quickly and efficiently locate and correct most vehicle concerns. This method is

the Symptom-to-System-to-Component-to-Cause (SSCC) diagnostic strategy.

As you have seen dedicated CNG fueled vehicles are unique in many ways. The differences in these

vehicles mean that the diagnosis and service procedures are also unique. This makes following a

diagnostic strategy even more critical.

Ford recommends the SSCC diagnostic strategy. To follow this strategy, all you have to do is follow the

words in the title.

SYMPTOM = VERIFIED VEHICLE CONCERN

1. First, determine the Symptom of the customer concern.

Ensure that you understand exactly what the customer is concerned about.

Try and determine if the concern is a malfunction or if it is a normal tendency of a CNG fueledvehicle. This is important because some customers may not be familiar with the normal operatingcharacteristics of a vehicle that is operating on CNG.

SYSTEM = IDENTIFY VEHICLE SYSTEM RESPONSIBLE FOR SYMPTOM

2. Next, determine which System on the vehicle could be causing the symptom.

There is no sense in checking the air pressure of the tires if the vehicle has no power.

On CNG fueled vehicles, this step requires that you determine if the symptom is being caused bythe CNG fuel system or by a base vehicle system.



COMPONENT = DETERMINE EXACTLY WHICH COMPONENT OFTHE SYSTEM NEEDS ADJUSTMENT OR HAS FAILED

3. Once you identify the particular system responsible for the symptom, you then need to determinewhich Component(s) within that system could be the cause for the customer concern.

Diagnostic tests are usually isolation tests. The idea behind them is to check the operation of aspecific component, without other components in the system affecting the component being tested.

On CNG fueled vehicles, this requires product knowledge, skill, and your ability to know how touse and interpret special tools.

SYMPTOM-TO-SYSTEM-TO-COMPONENT-TO-CAUSE (SSCC)DIAGNOSTIC STRATEGY (CONTINUED)

CAUSE = IDENTIFY AND CORRECT THE CAUSE OF THE FAILURETO PREVENT A REPEAT OF THE FAILURE

4. Once the failed component is identified, you should always try and determine the Cause of the failure.

For example, the component causing a system not to get power may be a blown fuse, but if youdon’t repair the short that caused the fuse to fail, then the new fuse will fail as well.



SERVICE AREA PRECAUTIONS

The following service area precautions should always be followed prior to bringing a dedicated CNG

vehicle into a service bay:

Ensure the CNG fuel system has no obvious leaks.

The vehicle should not be exposed to temperatures over 100° F (38° C).

Ensure that the vehicle is not parked within 10 feet (3 meters) of:

– Any source of heat

– Any source of open flame

– Any source of ignition (such as metal grinders or other spark-generating tools or devices)

– An overhead heater



PRELIMINARY DIAGNOSTIC STEPS

Whenever a vehicle is brought in with a customer concern, the following preliminary diagnostic stepsshould always be performed. Each of these steps is very important in determining and correcting thesource of a concern.

1. Verify customer concern. Determine whether the concern is caused by a malfunction or whether it isbecause the customer is not familiar with CNG-fueled vehicle operation.

2. Check OASIS, Ford (dedicated CNG and Multiport Bi-Fuel CNG Vehicles) TSBs, and vehicleservice history. OASIS may provide you with important information on any technical service bulletinsthat may have been issued for the vehicle. The service history may give you some insight to the kindof service the vehicle has had in the past and whether the current concern may be related to thisservice.

3. Perform a thorough visual inspection. Many vehicle concerns can be found and corrected byperforming a visual inspection. A loose wire, corroded ground, or disconnected sensor can have adramatic effect on vehicle operation. During your visual inspection, double-check the following:

Adequate fuel

Quarter-turn valve fully open (if equipped)

Fuse condition and security

Electrical connector condition and security

Damage, leaks and/or kinks in fuel lines and tank

Damage, leaks and/or kinks in vacuum lines and connectors

Damage, leaks and/or kinks in coolant hoses and fittings

Loose, damaged or incorrect type of spark plugs or secondary ignition wires

Damaged ignition system

Vehicle timing within specifications

4. Check for installation of non-factory add-on equipment. Improper installation of add-on equipmentcan cause incorrect electrical signals from reaching components and modules, which can result invehicle operating concerns.

5. On Multiport Bi-Fuel CNG Vehicles perform both key on engine off (KOEO) and key on enginerunning (KOER) self-tests in the gasoline mode. Using the New Generation STAR (NGS) tester,identify and service any base vehicle concerns prior to diagnosing the CNG fuel system. .

5. Retrieve continuous DTCs. Continuous codes indicate a fault that has occurred in the past (usuallyduring the previous 40 trips). These may indicate a fault that is still occurring or an intermittent faultthat may not currently be occurring.

Retrieving continuous DTCs is usually done with the NGS.

Retrieve DTCs from both the PCM and AFCM.

Refer to the workshop manual for the vehicle you are working on.



PRELIMINARY DIAGNOSTIC STEPS (continued.)

6. Perform key on engine off (KOEO) self-tests.

KOEO tests will identify current faults that can be detected with the engine off.

7. Perform key on engine running (KOER) self-tests.

KOER tests will identify current faults that can be detected with the engine running.

8. Diagnostic Sequence for Multiport Bi-Fuel CNG Vehicles.

When performing diagnostics on a Multiport Bi-Fuel CNG Vehicle, always check base gasolinevehicle systems before diagnosing CNG system faults.

This should be done because a marginal condition on a base vehicle system that will not cause amalfunction during gasoline operation may cause a concern during CNG operation. Example:Deteriorated secondary ignition wires that will not cause an engine miss when operating ongasoline may cause a miss when operating on CNG. This is due to the higher ignition temperatureof natural gas.



IDENTIFICATION AND RETRIEVAL OF CNG SYSTEM DIAGNOSTICTROUBLE CODES (DTCs)On a dedicated CNG and Multiport Bi-Fuel CNG Vehicles, the presence of a DTC in the CNG system isindicated by the illumination of the Malfunction Indicator Light (MIL).

The MIL will remain on while the fault condition actively continues or for the next two trips with noactive faults.

Note: A vehicle trip is defined as the operating state of the vehicle when the following criteria are met:– Start and warm-up sensor until ECT/CHT sensor indicates approximately 82 °C (180 °F)

– Idle for 45 seconds

– Accelerate to 45 mph at 1/4 throttle in approximately 10 seconds

– Drive at steady throttle at 30-40 mph for approximately 1 minute

– Drive 20-45 mph (no WOT) for 4 minutes

– Decelerate and idle for 10 seconds

– Accelerate to 55 mph at 1/2 throttle for approximately 10 seconds

– Steady throttle at 40-65 mph

The light will extinguish if the fault condition discontinues for more than two trips.

The fault code is stored and may be retrieved during service.

Dedicated CNG and Multiport Bi-Fuel CNG Vehicles have the capability to store CNG diagnostic

trouble codes (DTCs) in both the PCM and AFCM.

These codes can help to locate and diagnose the cause of a CNG system fault.

However, not all faults will set a DTC. In these cases, use of the Symptom Charts in the PC/ED manualis recommended.

For further information on DTC indications and retrieval, refer to the subsection of this lesson. For additionalinformation on the operation of the NGS, refer to the NGS Web Course.

NOTE: The AFCM will only store DTCs for faults relating to components that it monitors. These include:

Fuel tank pressure sensors

Fuel tank temperature sensors

Battery voltage

Fuel Injectors (Multiport vehicles only)



SERVICE PUBLICATION NAVIGATION

During diagnosis and service of CNG vehicles, you may need to refer to many different service

publications. It is essential that you are able to navigate through these publications to locate diagnosis

and service information. The following is a brief description of these publications.

Powertrain Control/Emissions Diagnosis (PC/ED) Manual - This publication will provide you withboth base and CNG system driveability diagnostic and emission information.

Workshop Manual - This publication will provide you with service information for both the basevehicle systems and the CNG fuel system.

Wiring Diagrams - This publication will give you electrical schematics, electrical component andconnector location and information for base vehicle systems and the CNG fuel system.

Service publications are available in multiple formats including:– Paper publications

– CD-ROM/DVD

– Web-based at the Professional Technician Society website which is linked through the Ford QC

Dealer.com

– Web-based at the Ford Fleet website at www.fleet.ford.com

Powertrain Control/Emissions Diagnosis (PC/ED) Manual

The Powertrain Control/Emissions Diagnosis (PC/ED) manual is the primary source for diagnostic

information for the CNG fuel system. This manual provides a step-by-step approach for diagnosing

driveability, emission and powertrain control system symptoms. Before beginning diagnosis, always reference

any Technical Service Bulletins (TSBs) or On-line Automotive Service Information System (OASIS)

information when this is available.

Information on Dedicated CNG and Multiport bi-fuel CNG systems is found in the conventional PC/

ED, not the OBD II Bi-Fuel LPG/CNG Powertrain Control/Emissions Diagnosis (PC/ED) Manual.

This manual is used in conjunction with the Body, Chassis, Electrical, Powertrain Workshop Manuals

and the Wiring Diagram Manuals. The Workshop Manuals are used to provide additional diagnostics

when directed by this manual. The Workshop Manuals are also used for component removal and

replacement information. Refer to the Wiring Diagram Manuals for vehicle specific wiring information

and component, connector and splice location.

The following is a description of the information contained in each section of the PC/ED.

Section 1: Description And Operation

This section contains description and operation information on powertrain control systems and

components. This section is designed to give the technician a general knowledge of the powertrain

control system. It should be used when general information about the powertrain control system is

desired, and is rarely referenced from other sections of the manual.



Section 3: Symptom Charts

All diagnosis begins in Section 3 with Step 1: Diagnostic Quick Test. If the Diagnostic Quick Test is

completed and no DTCs are received, the technician may be directed to Step 2: No DTCs Present Symptom

Chart Index (refer to Section 3 for details). The No DTCs Present Symptom Chart Index contains the list of

symptoms addressed in this manual, and will send the technician to the appropriate Step 3: No DTCs Present

Symptom Chart. If no DTCs are present and the vehicle symptom is not listed in the Step 2: No DTCs Present

Symptom Chart Index, the technician should go the appropriate Workshop Manual to continue diagnosis.

Powertrain Control/Emissions Diagnosis (PC/ED) Manual (continued)

Section 4: Diagnostic Subroutines

Section 4 contains the Powertrain Diagnostic Trouble Code (DTC) "Go To" Charts. These charts will be

referenced if a DTC is received in Section 3. Also included in this section are the Powertrain DTC

descriptions and list of possible causes.

Section 5: Pinpoint Tests

All the pinpoint tests are included in Section 5. Never enter a Pinpoint Test unless directed there. When

directed to a Pinpoint Test, always read the information and look at the schematic included at the beginning of

the Pinpoint Test.

Section 6: Reference Values

Section 6 contains the "Typical Diagnostic Reference Values" charts.

Section 2: Diagnostic Methods

The Diagnostic Methods section contains information on specific diagnostic tasks that are used during

diagnosis. Descriptions of specific diagnostic methods are included, as well as detailed instructions on how to

access or perform the tasks. This section provides the technician with step-by-step instructions for performing

routine diagnostic tasks.



Workshop Manual

Information on performing service and repair procedures on CNG vehicles is found in the vehicle

workshop manual.

The vehicle workshop manual is available in book, CD-ROM, and web-based (at the PTS website)formats.

Wiring Diagrams (EVTMs)

The standard Ford Wiring Diagram Manual (EVTM) contain wiring diagrams for both the base vehicle

systems and the CNG fuel system. In addition to diagrams of the vehicle wiring, information such as

component location, wiring connector diagrams, and other vehicle information can be found in the wiring

diagram manual.

Wiring diagrams are available in in book, CD-ROM, and web-based (at the PTS website) formats.



When diagnosing the CNG fuel system of dedicated CNG and Multiport Bi-Fuel CNG Vehicles, there

are unique component and system tests that may be required. Additionally, due to the unique nature of

CNG and of the components of the CNG fuel system service procedures require extra care and

attention to detail. It is essential that whenever servicing a CNG fuel system that all safety procedures

be followed, and that the procedures spelled out in the service publication be performed as described

without taking shortcuts. This section describes some of these tests and how to interpret their results

and some important service procedures.

WARNING: FOLLOW ALL WARNINGS AND CAUTIONS AS DESCRIBED IN THISSTUDENT REFERENCE GUIDE AND AS DESCRIBED IN THE SERVICEPUBLICATIONS WHEN PERFORMING ANY OF THE TESTS DESCRIBED IN THISSECTION.

COMPONENT AND SYSTEM TESTING AND SERVICE



Cooling System Pressure Testing

Cooling system pressure testing procedures are basically the same as on any other type of vehicle. However,because the high-pressure regulator of the CNG fuel system uses engine coolant, additional componentshave been added to the cooling system.

These additional components slightly change the use and interpretation of the cooling system pressuretest.

Connect the Pressure Tester as described in the base vehicle workshop manual.

When performing the leak-down portion of the cooling system pressure test, be aware that a drop inthe pressure may be the result of a coolant leak in the high-pressure regulator, its hoses or seals.

If the cooling system fails to maintain the specified pressure during the leak-down test, closely inspect thehigh-pressure regulator and all coolant connecting hoses.



WARNING: TO AVOID THE IGNITION OF FUEL VAPORS THAT ARE VENTED TOTHE ATMOSPHERE:

THE ENGINE MUST BE SHUT OFF.

EXTINGUISH ALL SMOKING MATERIAL.

NEVER ATTEMPT TO OVERPRESSURIZE THE CNG SYSTEM.

Turn the engine off.

Turn the selector knob on the fill nozzle to “VENT” position.

Connect the quick coupling, on the fill nozzle, securely to the system fill valve.

Turn the selector knob on the fill nozzle to the “ON” position.

Switch on the service pump. A noise will be heard as the cylinder begins to fill.

Watch the pressure gauge on the service pump.

When the gauge reads approximately 3000 or 3600 psi (vehicle and model year dependent), orwhen the fill pressure begins to move very slowly, the CNG tanks are full.

CNG REFUELING PROCEDURES

CNG Fueling

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NOTE: After filling, the operator may notice a variance in pressure as the vehicle stabilizes. CNG tank

pressure will vary with ambient air temperature.

At 70° F, tank pressure is approximately 3000 or 3600 psi. For every 10° F difference add or subtract100 psi. For example: If the air temperature is 80° F, then the tank pressure would be 3000 + 100 or3100 psi. If the air temperature is 60° F, then the tank pressure would be 3000 - 100 or 2900 psi.

Shut off service pump.

Place the selector on the fill nozzle to the “VENT” position. A short hiss of pressure is heard as a smallamount of natural gas is vented into vent hose.

Disconnect the quick coupling on the fill nozzle.

NOTE: A CNG vehicle with a 3600 psi fuel system can be fueled at a 3000 psi pump (although only to

3000 psi), however a CNG vehicle with a 3000 psi fuel system cannot be fueled at a CNG pump that

dispenses fuel at 3600 psi.

CNG REFUELING PROCEDURES (continued)



CNG CONTAMINATION

Natural gas for vehicles is taken from a gas utility’s distribution network. A compressor station is used

to dispense the fuel when filling a vehicle.

Many times, these compressors discharge excess oil that mixes with the natural gas.

Minute portions of this oil are acceptable and can be beneficial to lubricate the internal injectorcomponents.

But excess contamination is harmful and can deteriorate performance and cause excessive wear and,eventually, component failure.

Another concern is water contamination of natural gas.

Natural gas designated for residential use is allowed to have 7 pounds of water per 1 million cubicfeet of gas.

SAE standards for natural gas used in vehicles is 1/2 pound of water per 1 million cubic feet of gas.

CAUTION: Never use natural gas that has been liquefied then converted back to gas. This processremoves all lubrication qualities from the gas and will result in component damage.

The solution for contamination problems is proper filtration systems at the fueling stations.

Some gas utility companies have been slow to respond or acknowledge the problem.

Fuel contamination may result in intermittent leaks in the CNG fill valve. This is caused by water inthe fuel freezing during fueling, then holding the valve open until it melts. Particulate contaminationcan also cause the valve to stick open.

The technician should be mindful of the amount of oil and water found in the system during routine

maintenance (e.g., cleaning and changing the filters).

If a large quantity of oil or water is present in the system, the technician should recommend to the

customer the following items:

Change Filling Stations - The contamination will not necessarily be the same from location to location.

Accelerated Maintenance Schedule - By cleaning and changing the filters on a more frequent basis,the system can be kept cleaner.

NOTE: Multiport Bi-Fuel CNG Vehicles should run a minimum of 1 tank of gasoline every 60 days. Thisprevents the gasoline in the gasoline fuel tank from varnishing and helps prevent clogging of thegasoline fuel injectors.



Some CNG vehicles may have a fuel fill valve filter. This filter should be cleaned annually. The

following procedure should be used when servicing the fuel fill valve filter.

Vent fuel lines.

Disconnect the fuel tube from the rear of the fuel fill valve.

Remove the fuel fill valve straight fitting.

Using the fuel fill valve filter removal tool, remove the fill valve filter by turning the fill filtercounterclockwise.

FUEL FILL VALVE FILTER

Fuel Fill Valve Filter

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The coalescent filter removes water and particulate contamination from the CNG fuel system. It has a

drain plug that allows water to be drained at each oil change and a filter that is replaced on a normal

maintenance schedule (refer to vehicle owner’s manual for schedule).

Filter Removal

1. Bleed the fuel lines.

2. Place container under coalescent filter assembly.

3. Remove drain plug and allow all liquid to drain.

4. Remove coalescent filter housing from base by rotating the housing counterclockwise.

5. Move filter element back and forth while pulling it downward.

6. Remove and discard filter element and o-ring.

Filter Installation

1. Lubricate new o-ring seal with clean 5W-20 engine oil meeting Ford specification WSS-M2C153-F.

2. Install new o-ring and filter.

3. Install coalescent filter housing. Tighten to specifications.

4. Install drain plug and tighten to specifications.

COALESCENT FILTER SERVICE

Coalescent Filter Assembly


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Due to the use of fuel that does not meet SAE standards for CNG vehicles, concerns have arisen that

are caused by partially or completely clogged fuel injectors.

Symptoms of this concern include:

Rough Idle

No Start in Cold

Driveability concerns

Diagnosis and Service Procedure:

Perform normal diagnostics per Ford Service Procedures. If it is identified that the injectors are partially

or completely clogged perform the following procedure to clean the CNG Injectors:

1. Start vehicle and idle at 1500 rpm for 5 minutes, if the vehicle will not start due to clogged injectors,the injectors may be completely stuck closed. If this is the case, attempt to free them by applying 12Volts directly to the injector coil:

A. Apply battery voltage to the side of the injector connector to which the red wire circuit 361 connects.

B. Ground the other side of the connector momentarily and listen for an audible click to confirm thatthe injector has opened.

Caution: Do not ground the injector for more than 10 seconds. Prolonged grounding may

result in damage to the injector.

C. If an injector remains stuck, wait 10 seconds and repeat steps A and B.

Note: If the injector does not produce an audible click after three attempts, replace the injector (refer tovehicle workshop manual).

1. If injector operation is confirmed, perform the following procedure for cleaning the injectors.

2. Remove CNG coalescent filter bowl after properly venting the fuel line (per Ford CNG Venting Procedurefor Servicing Filter Bowl).

3. Check for dirt or oil in the filter bowl - Clean it if necessary.

4. Remove the coalescent filter element.

5. Fill the filter bowl to the top with Iso-Propyl Alcohol (with strength of at least 90%).

6. Reinstall the bowl (torque for bowl: 30 +/- 5 Ft-lb, torque for drain plug: 8 +/- 2 Ft-lb).

7. Start engine and idle at 1500 rpm for 10 minutes.

8. Repeat step 2 and Reinstall the Filter element and the bowl.

9. Test drive vehicle to confirm removal of rough idle.

In some cases of severe injector clogging, this procedure will have to be repeated. If the concern is not

corrected repeat the procedure as required. This procedure is explained in detail in TSB 01-22-1 for all

dedicated CNG vehicles and Multiport Bi-Fuel CNG Vehicles. TSB 01-23-1 explains fuel injector

cleaning for all other bi-fuel CNG vehicles.

FUEL INJECTOR CLEANING



FUEL TANK REMOVAL

CNG fuel tank removal procedures will vary based upon the model year and vehicle type being worked on.

Whenever fuel tank removal is required it is essential that the workshop manual procedures are strictly followed

with special emphasis on the safety procedures called out in the workshop manual.

Crown Victoria CNG Fuel Tanks

Multiport Bi-Fuel CNG Fuel Tank



When servicing dedicated CNG and Multiport Bi-Fuel CNG Vehicles, fuel line removal and

replacement is often required. CNG fuel systems use high-pressure stainless steel fuel lines that have o-

ring seals.

FUEL LINE SERVICE

High Pressure Fuel Line Fitting

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When servicing these, use the following precautions:

Whenever a fuel line fitting nut is loosened, the o-ring on the line must be replaced.

Use only the correct o-ring (yellow stripe), or an o-ring that the packaging specifies can be used forCNG, when replacement is required.

When connecting components to fuel lines, always get the fuel line fitting started into the componentfitting before tightening the component to the vehicle. This is important because CNG fuel lines arestainless steel and should not be bent.

When installing fuel tanks, always connect the fuel lines before tightening the tank retaining straps.

Once installed, always check fittings for leaks with liquid leak detector.



Fuel system leak testing is one of the most critical test procedures performed. Never assume that a vehicle has

no leaks in the fuel system.

There are two methods that are used to identify leaks in the fuel system:

The electronic leak detector (to narrow down the location of the leak).

The liquid leak detector (to pinpoint the exact location of the leak).

Both methods should be used whenever vehicle service is performed to verify the security of the system.

Always use the electronic leak detector first to avoid contamination by the liquid detector.

Most leaks in the fuel system will occur around fittings and connectors. Place special emphasis on thesewhen looking for leaks.

Always keep an eye out for damaged fuel lines. Even a small amount of impact damage to a fuel line canresult in an CNG leak.

Before attempting to determine if a fuel leak exists, ensure that the solenoid tank valves are open so thatample fuel can flow from the tank.

Fuel System Leak Testing

Rotunda Electronic Leak Detector

Electronic Leak Detector:

The Rotunda Electronic Leak Detector 134-00049 identifies CNG leaks electronically by detecting the presenceof hydrocarbons.

This type of equipment is sensitive to the presence of any hydrocarbons, which may give misleading results.

Any time the detector indicates a leak, verify the results with a liquid leak detector.

Liquid Leak Detector:

The liquid leak detector uses a glycerin-based liquid to identify leaks.

After applying the liquid, watch the suspect area closely.

If bubbles begin to expand from the area, a leak is indicated.



Fuel System Leak Testing (continued)

Leak Testing a Fitting

Whenever a fuel line fitting has been opened it must be check for leaks after reassembly. This must be done

using liquid leak detector.

When checking for leaks apply the liquid leak detector on the line fitting.

Watch for bubbles rising around the fitting (bubbles indicate there is a leak).

Leak Testing a Fitting

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Crown Victoria Vent Box Leak Test

Crown Victoria Vent Box Leak Test Tools

In the event the smell of natural gas is detected either in the vehicle passenger compartment or the

trunk of a dedicated CNG Crown Victoria, the vent box should be tested for a leak.

Refer to the workshop manual for exact procedures for the year vehicle you are working on. The followingis a general overview of the test procedure.

Close the fuel tanks using the manual lockdown on the solenoid tank valve.

Disconnect the fuel line and wiring harness between the upper and lower tank rack assemblies at the lowertank rack.

Install the vent box pressure test adapter in the flexible vent tube.

Use the Rotunda Evaporative Emission Tester 134-00056 to pressurize the vent box to 20 inches of water.

Monitor the pressure drop for two minutes. The pressure cannot decay below 14 inches of water.

If the pressure test fails, test all sealing surfaces with a liquid leak detector.

Correct the source of any CNG leaks (on the vehicle) and reinstall the vent box. Retest to verify repair;connect fuel lines and wiring connectors.

WARNING: LOCATE AND CORRECT SOURCES OF CNG LEAK ON VEHICLEBEFORE INSTALLING THE VENT BOX.

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WARNING:

VENTING OF FUEL REQUIRES THE USE OF A VENT STACK THAT ISAPPROVED AND EQUIPPED FOR THE PROCEDURE. FOLLOW LOCALREGULATIONS AND CONSULT YOUR LOCAL FIRE ANDENVIRONMENTAL AUTHORITIES FOR SPECIFIC REGULATIONS.

THE TOP OF THE VENT STACK MUST BE A MINIMUM HEIGHT ABOVETHE STRUCTURE TO WHICH IS ATTACHED. CONTACT LOCALAUTHORITY HAVING JURISDICTION TO DETERMINE CORRECT HEIGHT.

FUEL SYSTEM VENTING


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When servicing the fuel system of a dedicated CNG fueled vehicle, the fuel system usually must bevented.

Dedicated CNG vehicles may use three different methods for fuel system venting:

1. Fuel line venting at the fuel injection supply manifold (MY and Model dependent).

Vents the fuel system from the fuel injection supply manifold to the tank solenoids.

Required prior to replacement of any fuel system component.

Fuel lines are vented from the fuel injection supply manifold since the fuel pressure regulator is notdesigned to backflow reliably.

2. Fuel tank venting at the fill valve (on vehicles equipped with manual backflow MY and Modeldependent).

Should only be performed to replace an expired or damaged tank or to replace a damaged fuelsolenoid tank valve.

Must be confirmed with use of the override tool.

Requires that the vented solenoid be replaced once the override tool is used.

Required prior to fuel tank replacement or solenoid valve removal.

Can be performed only after solenoid diagnostics have been completed.

3. Fuel line and tank venting using vent tools on vehicles without manual backflow or fuel injectionssupply manifold Schrader valve (MY and Model dependent).

Can be used to vent either the tanks or the fuel system from the fuel injection supply manifold tothe tank solenoids.

The fuel system from the fuel injection supply manifold to the tank solenoids must be vented priorto replacement of any fuel system component (after verification of correct operation of tanksolenoids).

For tank replacement the complete venting of the fuel tank must be confirmed with use of theoverride tool.

Requires that the vented solenoid be replaced once the override tool is used.

Required prior to fuel tank replacement or solenoid valve removal.

Can be performed only after solenoid diagnostics have been completed.

These three venting procedures allow only the portion of the system being serviced to be vented. Alwaysrefer to the vehicle workshop manual for instructions on the correct procedure for venting the vehicleupon which you are working.

FUEL SYSTEM VENTING (continued)



Solenoid Tank Valve Diagnostics

As with most types of diagnostic tests, solenoid diagnostics use isolation tests to determine if the tank

solenoid valves are functional.

WARNING:

ALWAYS ASSUME THAT ALL FUEL SYSTEM COMPONENTS AREUNDER FULL SYSTEM PRESSURE AT ALL TIMES.

USE CAUTION WHEN SERVICING FUEL SYSTEM COMPONENTS.

Solenoid tank valve diagnostics are critical. As with all Pinpoint Tests, these test procedures must be

performed precisely and in the correct sequence. This is even more critical with CNG vehicles since fuel tanks

and lines are under very high pressure.

Always refer to the fuel system section of the workshop manual for the correct procedures when diagnosing

CNG solenoid tank valves.

NOTE: Some threads on AFVs are Left-Handed. Always refer to service publications when performing

vehicle and component service procedures.



NOTES

DEMONSTRATION 1


CONTENTSOBJECTIVES



has acquired from Lesson 4.


information found in Lesson 4.

– Enable the students to see and practice

diagnostic procedures.

– Provide the students with service publica-

tion navigation practice.

Demonstration 1 Worksheet

Alternative Hands-On Worksheet

DEMONSTRATION 1 - CNG VEHICLE DIAGNOSTICS

DEMONSTRATION 1


Directions: This vehicle has a customer concern of "runs rough." Follow along with your instructor to

diagnose this concern. Answer the questions below as the diagnosis is performed. Also list the test steps that

are performed and their results in the table provided.

1. Does the reason for the engine roughness seem to be the result of a miss in several cylinders, or a singlecylinder? _____________________________________________________________________________________________________________________________________________________

2. List any DTCs that are present._______________________________________________________

3. Based upon this preliminary diagnosis, which of the systems or components listed below could bea likely source of this miss?

A. Idle Air Control (IAC) - YES or NO. Why? ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

B. Mass Air Flow (MAF) - YES or NO. Why?___________________________________________________________________________________________________________________________

C. Secondary Ignition System - YES or NO. Why?______________________________________________________________________________________________________________________________________________________________________________________________________

D. Fuel Delivery System - YES or NO. Why? _________________________________________________________________________________________________________________________________________________________________________________________________________

E. Exhaust System - YES or NO. Why? ______________________________________________________________________________________________________________________________________________________________________________________________________________

F. PCV System - YES or NO. Why? _________________________________________________________________________________________________________________________________________________________________________________________________________________

DEMONSTRATION 1 WORKSHEETDEDICATED CNG OR MULTIPORT BI-FUEL CNG VEHICLE DIAGNOSIS


DEMONSTRATION 1


DEMONSTRATION 1 WORKSHEETDEDICATED CNG OR MULTIPORT VEHICLE DIAGNOSIS


4. Continue the diagnosis using the service publications and list the diagnostic test steps and their results in thetable below.

PETSTSETCITSONGAID STLUSER

DEMONSTRATION 2


DEMONSTRATION 2


CONTENTSOBJECTIVES







solenoid tank valve diagnostic procedures.


fuel venting procedures.



Demonstration 2 Worksheet

DEMONSTRATION 2 - DEDICATED CNG OR MULTIPORT BI-FUELVENTING AND SOLENOID DIAGNOSIS

DEMONSTRATION 2


DEMONSTRATION 2 WORKSHEETDEDICATED CNG OR MULTIPORT BI-FUEL FUEL VENTING

AND SOLENOID DIAGNOSISSTUDENT ANSWER SHEET

Directions: Follow along with your instructor while the class performs fuel venting and solenoid

diagnosis procedures. Answer the questions below as the activity is performed.

1. A CNG fueled vehicle should not be parked within 10 feet of what three things in a workshop?

__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

PAGE#_______

2. If a vehicle requires that a fuel tank be vented, what must be determined before venting can beperformed? ____________________________________________________________________PAGE#_______

3. When is fuel line venting required? ________________________________________________________________________________________________________________________________PAGE#_______

4. When is fuel tank venting required? _______________________________________________________________________________________________________________________________PAGE#_______

5. What service publication (your Student Reference Guide is not a service publication) contains informationfor diagnosing solenoid tank valves? ________________________________________________PAGE#_______

6. During venting of fuel from a CNG tank, why is it essential that the vehicle be grounded?____________________________________________________________________________________________________________________________________________________________PAGE#_______

7. You are preparing to perform solenoid diagnostics. After disconnecting the solenoid tank valve connectors,you attempt to run the vehicle out of fuel. After 10 minutes the vehicle still does not stall. What does thisindicate? _______________________________________________________________________PAGE#_______

8. You are performing solenoid diagnostics on a vehicle with a manual backflow feature and full fueltanks. You have installed the vent tool and disconnected the electrical connectors to the fuel tanksolenoids. While monitoring the pressure gauge on the vent tool, you have no pressure at the bleedvalve after 1 minute. What does this indicate? ________________________________________________________________________________________________________________________PAGE#_______

9. To verify tank solenoid status, in what sequence should the fuel tanks be vented (on multiple fuel tankvehicles based on the solenoid tank valve status)? _________________________________________PAGE#_______

CONTINUED ON NEXT PAGE

DEMONSTRATION 2


10. Where can you find information on the replacement interval of the coalescent filter?______________________________________________________________________________PAGE#_______

11. What lubricant should be used on the o-rings of the coalescent filter when the filter element is replaced?______________________________________________________________________________PAGE#_______

12. When connecting fuel lines to system components, why should you always get the line fitting nutstarted into the component fuel line fitting before tightening the nut?______________________________________________________________________________PAGE#_______

13. What are the two methods for checking fuel lines for leaks?______________________________________________________________________________PAGE#_______

14. After installing fuel lines and pressurizing the system, what should always be done?______________________________________________________________________________PAGE#_______

DEMONSTRATION 2 WORKSHEETDEDICATED CNG OR MULTIPORT BI-FUEL FUEL VENTING

AND SOLENOID DIAGNOSISSTUDENT ANSWER SHEET

ACTIVITY 4


ACTIVITY 4


CONTENTSOBJECTIVES






– Enable the students to practice diagnostic

procedures.



Activity 4 - Worksheet Q (Hands-On)

Activity 4 - Worksheet R (Hands-On)

Activity 4 - Worksheet S (Written)

Activity 4 - Worksheet T (Written)

ACTIVITY 4

ACTIVITY 4


ACTIVITY 4 — WORKSHEET Q (Hands-On)DEDICATED CNG VEHICLE DIAGNOSIS


Directions: Go to the dedicated CNG classroom vehicle and use the information in your Student

Reference Guide and the service publications to perform the tasks and answer the questions below.

1. Review the vehicle repair order. What is listed as the customer concern? _____________________

2. While the vehicle was sitting in the lot, one of the other technicians thought that he detected thesmell of gas. What should you do before bringing the vehicle into the service bay?___________________________________________________________________________________________

3. Perform a leak test on the vehicle. Note any areas that you suspect may be leaking. __________________________________________________________________________________________

4. Perform the preliminary diagnostic steps. What are the results of these steps? _____________________________________________________________________________________________________________________________________________________________________________

5. When diagnosing this concern, what publication will provide you with diagnostic direction?______________________________________________________________________________

6. If any DTCs were present, where in this publication should you look for the specific pinpoint testthat you need to perform? _________________________________________________________

WORKSHEET CONTINUED ON NEXT PAGE

ACTIVITY 4


ACTIVITY 4 — WORKSHEET Q (Hands-On) (continued)DEDICATED CNG VEHICLE DIAGNOSIS


7. Diagnose the concern. List the diagnostic steps you perform and their results in the table below. NOTE:THE NUMBER OF ROWS IN THE TABLE DOES NOT INDICATE THE NUMBER OF STEPS THATMUST BE PERFORMED. USE ADDITIONAL PAPER IF REQUIRED.

8. What are the results of your diagnosis? Note: List component names and electrical circuits that may beinvolved. ______________________________________________________________________

9. If you repaired this concern, what should you do before returning the vehicle to the customer?______________________________________________________________________________

RETURN THE WORKSTATION TO THE CONDITION THAT YOU FOUND IT

END OF WORKSHEET


ACTIVITY 4


ACTIVITY 4 — WORKSHEET R (Hands-On)MULTIPORT BI-FUEL CNG VEHICLE DIAGNOSIS


Directions: Go to the Multiport bi-fuel classroom vehicle and use the information in your Student

Reference Guide and the service publications to perform the tasks and answer the questions below.

1. Review the vehicle repair order. What is listed as the customer concern? ___________________________________________________________________________________________________

2. While the vehicle was sitting in the lot, one of the other technicians thought that he detected thesmell of gas. What should you do before bringing the vehicle into the service bay? ___________________________________________________________________________________________

3. Perform a leak test on the vehicle. Note any areas that you suspect may be leaking. __________________________________________________________________________________________

4. Perform the preliminary diagnostic steps. When checking for DTCs on a bi-fuel vehicle, whichcontrol module should you retrieve DTCs from first?____________________________________

5. List any DTCs found in the control modules.PCM__________________________________________________________________________AFCM ________________________________________________________________________

6. When diagnosing this concern, list the publication and section of the service publication that willprovide you with diagnostic direction ? ______________________________________________

WORKSHEET CONTINUED ON NEXT PAGE

ACTIVITY 4


ACTIVITY 4 — WORKSHEET R (Hands-On) (continued) MULTIPORT BI-FUEL CNG VEHICLE DIAGNOSIS


8. Diagnose the concern. List the diagnostic steps you perform and their results in the table below. NOTE:THE NUMBER OF ROWS IN THE TABLE DOES NOT INDICATE THE NUMBER OF STEPS THATMUST BE PERFORMED. USE ADDITIONAL PAPER IF REQUIRED.

9. What are the results of your diagnosis? Note: List component names and electrical circuits thatmay be involved. _______________________________________________________________

10. If you repaired this concern, what should you do before returning the vehicle to the customer?______________________________________________________________________________

RETURN THE WORKSTATION TO THE CONDITION THAT YOU FOUND IT

END OF WORKSHEET


ACTIVITY 4


ACTIVITY 4 — WORKSHEET S (Written)SERVICE PUBLICATION NAVIGATION


Directions: Use the information you have learned and the publications provided to answer the


1. The following is a list of preliminary diagnostic steps. Use the student guide to determine the correct sequencein which these steps should be performed, then place a number next to each step to indicate it’s position inthe sequence.

2. A customer brings a dedicated 2001 CNG Crown Victoria into your facility with a concern of“backfiring” during deceleration. What publication will provide you with diagnostic direction?______________________________________________________________________________

3. Which section of this publication provides you with a description of the natural gas fuel system?______________________________________________________________________________

4. In what section of this publication will you find the "Symptom Charts"? _______________________

5. Based on the symptom listed in question 2, and assuming that there are no DTCs stored in any controlmodule memory, which symptom chart should you refer?____________________________________

6. Which pinpoint test are you directed to for this symptom? ____________________________________

7. You are working on a dedicated CNG vehicle that requires replacement of the filter element inside thecoalescent filter. What service publication will provide you with removal and installation information forthis component? __________________________________________________________________

8. The AFCM will store DTCs for faults relating to which two sensors? _______________________________________________________________________________________________________

END OF WORKSHEET

STEP SEQUENCE DIAGNOSTIC PROCEDURES

Perform KOER test

Check OASIS and TSBs

Verify concern

Check installation of non-factory equipment

Perform visual inspection

Perform KOEO tests

Retrieve continuous DTCs

ACTIVITY 4


NOTES

ACTIVITY 4


ACTIVITY 4 — WORKSHEET T (Written)SERVICE PUBLICATION NAVIGATION


Directions: Use the information you have learned, the publications provided, and the data table on the next

page to answer the following questions.

1. What cell numbers of the wiring diagrams contain engine controls schematic and connectorinformation for a Dedicated CNG 2001 E-Series truck? _________________________________

2. According to the 2001 PC/ED manual, what are the possible causes for DTC P0192 that are specificfor CNG vehicles?________________________________________________________________

3. On a Dedicated 2002 E-Series Truck, what is the correct torque for tightening a replacement fuel tanktemperature sensor? ______________________________________________________________

4. A customer brings an 2001 E-Series Truck to you with the concern of "vehicle range has suddenlydecreased".

You perform preliminary diagnostics and find no DTCs and no engine operation issues.

This leads you to suspect that a solenoid tank valve is stuck closed.

The vehicle is equipped with midship fuel tank, rear aft-axle fuel tank, forward aft-axle fuel tank, andextended range fuel tank.

Use the vehicle service publications and the information on the Data Sheet on the next page to identifythe cause of this concern.

PETSTSET STLUSER PETSTSETFOESOPRUP

5. Using the SSCC diagnostic method, what component is the source of the concern? ___________________________________________________________________________________________

END OF WORKSHEET

ACTIVITY 4


Directions: Use the Data Table below to answer question 4. This is done by comparing the service publication

pinpoint test steps to the pinpoint test steps listed below. The RESULTS COLUMN of the table lists the results of

the tests you perform, use these results to select the next step that must be performed. Continue doing this until

you've identified the cause of the concern. NOTE: SOME STEPS BELOW ARE NOT USED IN THE

DIAGNOSIS AND ARE ONLY INCLUDED AS DISTRACTORS. Select only the steps that are required.

DATA TABLE

PETSTSET STLUSER

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ACTIVITY 4 — WORKSHEET T (Written) SERVICE PUBLICATION NAVIGATION


ACTIVITY 4


NOTES

CNG SAFETY APPENDIX

1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles Appendix 1 - 1 March, 2004

APPENDIX 1: COMPRESSED NATURAL GAS SAFETY

The information presented in this appendix is for use as a supplement to that presented in the Alternative Fuel

Vehicle (AFV) Web-Based Course.

Appendix 1 - 2 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles

CNG SAFETY APPENDIX

March, 2004

Natural Gas Vehicle Fuel System Standards

The National Fire Protection Association (NFPA) has specified Technical Standard #52 for the design and

building of CNG fuel systems. The Canadian Gas Association (CGA) has adopted similar standards.

These standards also recommend or prohibit certain service procedures for natural gas fuel systems.

Many states and provinces have adopted these technical standards as law. There are also other local laws that applyto CNG fuel system service and fuel handling.

Many of the WARNINGS and service precautions described in this program are based on NFPA Standard #52.These practices are required for safety and must be followed.

Note: Many states and provinces regard as law NFPA #52, or the CGA standards respectively. There are also

other local laws that apply to CNG fuel systems, and they should be observed.

WARNING:

OBSERVE THE FOLLOWING PRECAUTIONS DURING SERVICE OF CNGVEHICLES.

FAILURE TO OBSERVE EACH OF THESE WARNINGS COULD RESULT INFIRE OR EXPLOSION IF FUEL IS IGNITED, AND ASPHYXIATION FROMTHE RELEASE OF NATURAL GAS.

Avoiding Fire or Explosion Hazards

WARNING:

DO NOT PARK OR SERVICE A CNG FUELED VEHICLE NEAR ANYSOURCE OF FIRE, SUCH AS OPEN FLAME, CIGARETTES OR SMOKINGMATERIALS, SPARKS, EXCESSIVE HEAT, WELDING, OR BODYGRINDING EQUIPMENT.

AVOID PLACING THE VEHICLE NEAR ELECTRICAL EQUIPMENT THATDISCHARGES SPARKS THROUGH NORMAL OPERATION, FOR EXAMPLE,MOTORS, ELECTRICAL SWITCHES, AND RADIO TRANSMISSIONEQUIPMENT.

Vent the CNG system using the recommended service procedures before storing a CNG vehicle indoors. Avoid

servicing a CNG vehicle with a natural gas leak indoors. Determine the source of the leak, vent the fuel system as

necessary then repair the natural gas leak. If any source of fire or ignition contacts natural gas, a fire could result.

If the fuel is confined and ignited in an enclosed, unventilated area, an explosion could result.

Be alert for the odor of natural gas. Natural gas is normally colorless and odorless. As a safety measure, a scent(ethyl mercaptan) is added to aid detection of fuel leaks.

Do not smoke or carry lighted tobacco when servicing or handling CNG fuel system components.

Store natural gas fueled vehicles and components away from heat, fire and any source of sparks.

Because natural gas is lighter than air, accidentally released gas will accumulate near the ceiling of a building.

CNG SAFETY APPENDIX


Venting CNG FuelNatural gas can be vented (discharged) into the atmosphere. However, when performing this procedure, thesteps described in the following warning must be observed.

WARNING:

ALWAYS VENT CNG TANKS IN A WELL-VENTILATED AREA THAT ISAPPROVED AND EQUIPPED FOR THE PROCEDURES.

EXTINGUISH ALL SMOKING MATERIALS.

NEVER VENT NEAR OPEN FLAME, HEAT SOURCES AND SPARKS.

ALWAYS USE APPROVED VENTING TOOLS AND PROCEDURES ASDESCRIBED IN THE SERVICE MANUAL.

NEVER DISCHARGE GAS BY OPENING THE TANK VALVES. HIGHPRESSURE CAN CAUSE SERIOUS INJURY.

ALWAYS GROUND THE VEHICLE AND NATURAL GAS SYSTEM. HIGHPRESSURE ESCAPING CAN CAUSE STATIC ELECTRICITY BUILDUP ANDSUBSEQUENT SPARKING.

Note: Copies of the National Fire Protection Association (NFPA) regulations can be purchased by writing or

calling:

National Fire Protection Association

1 Batterymarch Park, P.O. 9101

Quincy, MA 02269-9101

Toll Free Phone 1-800-344-3555

VENTING OF FUEL TANKS REQUIRES THE USE OF A VENT STACKTHAT IS APPROVED AND EQUIPPED FOR THE PROCEDURE. FOLLOWLOCAL REGULATIONS AND CONSULT YOUR LOCAL FIRE ANDENVIRONMENTAL AUTHORITIES FOR SPECIFIC REGULATIONS.

USE ONLY ELECTRICALLY CONDUCTIVE SEALANT ON NATURAL GASLINES. NEVER USE CONVENTIONAL TEFLON TAPE OR PIPE SEALANT.


CNG SAFETY APPENDIX

March, 2004

CNG Fuel Tank Safety

The tank used for natural gas is designed and manufactured to meet requirements of either NGV 1 or NGV 2.

• This is a series of standards as adopted by the American National Standards Institute (ANSI) and the AmericanGas Association (AGA).

• This standard contains specifications for the material, design, manufacture and testing of serially produced,refillable containers intended only for the storage of compressed natural gas for vehicle operations.

NGV 1 CNG tanks are made of high strength steel.

NGV 2 CNG tanks consist of a metal liner reinforced with resin impregnated continuous filament.

CONTOUR tanks are rated for use at 3000 psi.

These tanks are rated for use at 3000 psi (CONTOUR, CROWN VICTORIA) and 3600 psi (E&F-SERIES

TRUCKS).

WARNING: TANKS SHOULD NEVER BE OVERPRESSURIZED.

If damage to the tank is observed during maintenance/repair, the tank must be inspected and approved by qualified

personnel. If the tank is rejected, the tank must be replaced before the vehicle is returned to service.

THE TANK MUST BE VISUALLY INSPECTED EVERY 36 MONTHS OR36,000 MILES (58,000 KM), WHICHEVER COMES FIRST, TO MAINTAINCOMPLIANCE WITH FEDERAL REGULATION.

THE SERVICE LIFE OF A CNG FUEL TANK IS 15 YEARS FROM THE DATEOF MANUFACTURE LISTED ON THE TANK'S LABEL.

IF THE TANK LABEL IS MISSING OR UNREADABLE, THE TANK MUST BEREPLACED.

A TANK THAT DOES NOT PASS THE INSPECTION CRITERIA MUST BEREPLACED BEFORE THE VEHICLE IS RETURNED TO SERVICE USINGNATURAL GAS.

WARNING:

CNG SAFETY APPENDIX


VISUAL INSPECTION

• The visual inspection is for external damage and deterioration.

• The inspection must be performed by QUALIFIED PERSONNEL in accordance with the manufacturer’sestablished inspection criteria and the procedures outlined in pamphlet C-6.4 from the Compressed Gas

Association (CGA).

• A technician that finds tank damage and/or deterioration must note this on the repair order. This damagemust be communicated to the customer prior to releasing the vehicle.

• Levels of tank damage determine whether the damaged tank can be repaired or must be replaced. Theselevels of damage will be explained later in this section.

QUALIFIED PERSONNEL are those that are so designated by the Department of Transportation and

prevailing authorities responsible for containers used to carry, contain and/or transport gas, hazardous materials

and similar materials.

The address of the Compressed Gas Association is:Compressed Gas Association

1725 Jefferson Davis Hwy.

Arlington, VA 22202

(703) 412-0900

PAINTING A CNG VEHICLE

If a CNG bi-fuel vehicle requires painting, and the vehicle will be placed in a paint oven, the CNG tank must be

vented (emptied of fuel). This is done to prevent an overpressure condition during a soak in the paint oven.

WARNING: FAILURE TO COMPLETELY EMPTY THE FUEL TANK PRIORTO THE VEHICLE BEING PLACED IN A PAINT OVEN CAN CREATE AFIRE AND EXPLOSION HAZARD.

TANKS INVOLVED IN ACCIDENTS:

CNG bi-fuel vehicles that have been involved in an accident must have the fuel tank inspected and approved by

PRESSURE RELIEF DEVICE – Additionally, all CNG tank valves have a lead insert inside that will melt if the

tank is exposed to temperatures in excess of 100° C (212° F). This will allow the pressure inside the tank to be

relieved, in the event that the tank is exposed to excessive heat or a fire.

Note: The pressure relief device is a separate part from the solenoid tank valve used on Contour bi-fuel

vehicles, while it is part of the solenoid tank valves used on all other CNG fueled vehicles.

qualified personnel before being returned to service.

WARNING: TANKS THAT HAVE BEEN SUBJECT TO FIRE MUST BECONDEMNED AND REMOVED FROM SERVICE.


CNG SAFETY APPENDIX

March, 2004

WARNING:

INCORRECT USE OF THE MANUAL LOCKOUT/MANUAL BYPASSFEATURE OF A 1996-1999 CONTOUR SOLENOID TANK VALVE CANCAUSE EXCESS PRESSURE IN THE FUEL TANK.

THIS EXCESS PRESSURE MAY CREATE A FIRE OR EXPLOSIONHAZARD.

Solenoid Tank Valves

CNG vehicles can have any one of three different types of tank valves. The following lists the type of tank valves

used on the various CNG vehicles.

CNG/Gasoline Bi-Fuel Vehicle Tank Valve

1996 E & F-Series - Manual Tank Valve with external pressure relief device (PRD).

1998-2002 E & F-Series - Solenoid Tank Valve with internal PRD.

1996-1999 Contour - Solenoid Tank Valve with external PRD.

Dedicated CNG Vehicle Tank Valve

1996-2002 Crown Victoria - Solenoid Tank Valve with internal PRD.

1997-2002 E & F-Series - Solenoid Tank Valve with internal PRD.

Most CNG vehicles have electrically actuated solenoid tank valves. These are normally closed valves that are

actuated when the ignition key is turned on.

CNG SAFETY APPENDIX


Fuel System Modifications

WARNING:

DO NOT MODIFY THE FUEL SYSTEM OR COMPONENTS, OR REPLACECOMPONENTS WITH PARTS THAT DON’T MEET FORD SPECIFICATIONS.

THE CNG FUEL SYSTEM IS DESIGNED AND BUILT TO CONFORM TO THENATIONAL FIRE PROTECTION ASSOCIATION STANDARD # 52, ANDSIMILAR CANADIAN GAS ASSOCIATION STANDARDS, WHICH DEFINETHE SPECIALLY APPROVED MATERIALS, COMPONENTCONSTRUCTION, AND SYSTEM CONFIGURATION REQUIRED FOR CNGFUEL SYSTEMS.

IN ADDITION, THE PARTICULAR SYSTEM INSTALLED ON ALL VEHICLESIS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OFDIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTEDCONFIGURATION THAT COULD RESULT IN FIRE, EXPLOSION, ANDPERSONAL INJURY, OR CAUSE ENGINE DAMAGE FROM INCORRECTFUEL METERING.

THE USE OF FORD SPECIFIED PARTS, AVAILABLE AT AN AUTHORIZEDFORD DEALER, IS RECOMMENDED.


CNG SAFETY APPENDIX

March, 2004

Health Hazards

WARNING:

• AVOID INHALING NATURAL GAS OR OCCUPYING CONFINED AREASCONTAINING NATURAL GAS.

• IN LARGE QUANTITIES, NATURAL GAS CAN DISPLACE ENOUGHOXYGEN TO MAKE THE SURROUNDING AIR UNFIT TO BREATHE, ANDPOSSIBLY CAUSE ASPHYXIATION.

• IF A PERSON BREATHES NATURAL GAS OR AIR WHICH LACKSOXYGEN DUE TO THE PRESENCE OF NATURAL GAS, HEADACHE,DIZZINESS, AND WEAKNESS IN THE EXTREMITIES CAN RESULT.

• IN THE EVENT OF ASPHYXIATION FROM INHALING NATURAL GAS,MOVE THE VICTIM IMMEDIATELY TO FRESH AIR AND CONTACT APHYSICIAN OR MEDICAL EMERGENCY PERSONNEL FOR ARTIFICIALRESPIRATION OR OTHER REQUIRED TREATMENT.

• IF THE ODOR OF NATURAL GAS IS PRESENT IN AN AREA, WARN ALLPERSONS IN THE AREA TO EXTINGUISH ALL FLAMES AND TOBACCO.SHUT OFF ELECTRICAL AND AIR POWER EQUIPMENT AND EVACUATETHE AREA IMMEDIATELY. VENTILATE THE AREA UNTIL THE ODOR OFGAS IS NO LONGER PRESENT.

NGS APPENDIX

Appendix 2 - 1March, 20041999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles

APPENDIX 2: AFV NEW GENERATION STAR TESTER OPERATION

The information presented in this appendix is for use as a supplement to that presented in the AFV New

Generation STAR (NGS) Web-Based Course.

NGS APPENDIX

1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG VehiclesAppendix 2 - 2 March, 2004

Alternative Fuel Vehicle (AFV) DTC Retrieval

Fault codes for both the base vehicle and AFV systems can be retrieved and cleared using the New Generation

Star (NGS) tester. The following are the procedures for retrieving AFV trouble codes.

1. Insert correct program card into NGS.

2. Connect the NGS into the 16-pin OBD II data link connector (DLC).

3. Turn the ignition key to the ON position:

4. Program the appropriate information into the VEHICLE AND ENGINE SELECTION menu.

NGS Main Menu

BF 5-1

NOTE: 1998 vehicles can be tested for MIL (PCM) and AFCM codes only. All AFCM PIDS must be pulled

with GFI card (Rotunda Part #164-R0904) and Cable (Rotunda part #164-R0906). PIDS are viewed by

connecting the NGS to the J/108 connector at the VCL.

NGS APPENDIX


6. Perform DATA LINK DIAGNOSTICS to ensure that the J1850 network is functional.

Alternative Fuel Vehicle (AFV) DTC Retrieval (continued)

7. If a fault is indicated in the J1850 data bus, correct the fault and recheck the vehicle symptom before performingany further diagnostic tests.

Selecting Data Link Diagnostic Menu

BF 5-2

BF 5-1A

5. Next, select DIAGNOSTIC DATA LINK from the menu and press the trigger.

Selecting Diagnostic Data Link Menu

NGS APPENDIX



8. For AFV system diagnostics, select the AFCM MODULE (for base vehicle system diagnostics, selectPOWERTRAIN CONTROL MODULE).

Selecting AFCM Module Diagnostics

The AFCM advisory screen will appear to notify you that there are similar PIDs and DTCs to thoseused for the PCM. In the AFCM mode these PIDs and DTCs may have a different meaning thanthose found for the PCM.

AFCM Advisory Screen

BF 5-3

BF 5-4

NGS APPENDIX



10. Select RETRIEVE / CLEAR CONTINUOUS DTCs.

11. Press START.

9. Select the DIAGNOSTIC TEST MODES menu.

Selecting Diagnostic Test Mode Menu

Retrieving DTCs

BF 5-5

BF 5-6

NGS APPENDIX


14. DTCs should be cleared whenever directed by a pinpoint test and after performing vehicle service. Theprocedure for clearing codes is to:

Retrieve DTCs as previously described.

Once DTCs have been retrieved, press the CLEAR button (7).

If a code reappears, a fault is still present. If, after correcting all DTCs or if no DTCs are present, thesymptom still exists, refer to the Specific Condition Diagnostics Chart in the service manual supplement(1998) or the DTC chart in the PC/ED manual (1999 and later).

Clearing Alternative Fuel Vehicle (AFV) DTCs

12. Any codes present will then be displayed.

13. Write down all DTCs displayed. Refer to the Specific Code Diagnostics chart in the service manual supplement(1998 MY) or the PC/ED Manual (1999 MY and later) for diagnostic information on any DTCs present.

NGS Displaying DTCs

BF 5-7

NGS APPENDIX


Selecting PID Menu

There are situations where a sensor or component has deteriorated; yet its signal is not outside the

programmed calibrations of the module.

In these cases, operation of the vehicle may be affected, yet no DTC will be stored in memory.

For this reason, the NGS has the Parameter Identification Data (PID) mode.

The PID mode of the NGS allows you to see the signal as interpreted by the module.

In this way, you can watch the signal and determine if it is responding within specifications, or if itsoperation is erratic or slow.

The following procedure allows you to enter the PID menu, select, view and record PIDs:

1. To enter the PID menu, first, enter the AFCM menu in the DIAGNOSTIC DATA LINK menu, as you did toretrieve codes.

2. Then, enter the PID DATA MONITOR AND RECORD menu.

NGS Parameter Identification Data (PID) Function

BF 5-8

NOTE: 1998 vehicles can be tested for MIL (PCM) and AFCM codes only. All AFCM PIDS must be pulled

with GFI card (Rotunda Part #164-R0904) and Cable (Rotunda part #164-R0906). PIDS are viewed by

connecting the NGS to the J/108 connector at the VCL.

NGS APPENDIX


AFCM PID Screen

3. A PID screen similar to the one shown here will appear.

4. To select an individual PID, first, use the scroll bar to highlight the PID you wish to select, then press trigger.An asterisk will appear next to the PID, indicating that it has been selected for viewing and recording.

5. To select a BLOCK (group) of PIDs at the same time, press the BLOCK button (button 6), and then pressTRIGGER. As you rotate the scroll bar through the PIDs, they will be highlighted.

6. When you have highlighted the desired group, press TRIGGER again and asterisks will appear next to theselected PIDs.

7. To select the maximum number of PIDs for viewing, press the MAX button.

NGS Parameter Identification Data (PID) Function (continued)

8. Press the START button and the PID values will appear. You can now watch the signals to determine if theyare acting normally, or if they could be the cause of the concern.

9. The NGS not only can monitor PID, but it can record it as well. This function is very useful when driving avehicle or when diagnosing an intermittent fault.

When you pushed the START button to view the PID data, the NGS began recording the data.

The NGS will continue recording PID data until the memory fills.

When the memory is full, the data at the beginning of the recording will drop off and new data will bestored.

The amount of time it takes to fill the memory will depend on the number and complexity of the PIDsselected.

BF 5-9

NGS APPENDIX


For example, assume you are driving a vehicle with a poor performance concern and no DTCs are present.

– This pinpoint test specifies certain PIDs to view.

– Since you cannot view the PIDs and drive at the same time, you decide to record the PIDs duringvehicle operation.

– Select the PIDs you wish to view (those specified by the test and any others you feel may behelpful).

– While driving, you notice a sudden loss of engine power. Press the trigger to capture the data.

– You can now drive the vehicle until the recorder memory is full or you can press the trigger againto save the data before the memory fills.

– Data will be saved from both before and after the trigger was pressed to capture data. This allowsyou to see the data before, as well as after the concern occurred.

10. Along the bottom of the screen the instructions tell you to press trigger to CAPTURE data:

Once the trigger is pressed, the NGS will continue to record data.

However, data at the beginning of the recording will not drop off.

The NGS will continue to save data until you press TRIGGER again to SAVE the data, or until recordermemory is full.

In this way, the NGS will have data in memory both before and after you pressed the TRIGGER toCAPTURE data.


NGS APPENDIX



11. Once you press the trigger to save the data, a message will appear informing you that the data is being saved.This screen will appear.

12. Always store data before attempting to view the recording.

– Highlight the area of the NGS memory that you want to store the recording, then press TRIGGER.

– The NGS will warn you that any existing recording in that area will be overwritten.

13. Press TRIGGER again and the data will be saved in the area you selected.

14. To view the recording, select VIEW RECORDING area or return to the main menu.

15. Highlight the VIEW RECORDING areas and press TRIGGER. The NGS will ask you to select the recordingarea you wish to view.

16. Highlight the area you wish to view and press TRIGGER.

17. Once you have brought up the stored data, you need to select which sensor data you wish to view:

Single Selection - To make a single selection, scroll to that selection and press TRIGGER. An asterisk willappear before the selected PID.

MAX - The MAX button will select only the first or top four PIDs, regardless of the number that areavailable in the recording.

CLEAR - The CLEAR button will deselect all PIDs.

Saving a PID Recording

BF 5-10

NGS APPENDIX


PID Table Display

Once you have selected a PID or several PIDs to view, you need to choose how you want to view them. The

options are table display and graph display. Either of the two formats can be printed as well.

TABLE DISPLAY:

The table display will allow you to view up to four of the recorded PIDs at a time, at various speeds. The

“Point-in-Time” recording will display on the left side of the screen.

To move forward through the recording, turn the scroll dial clockwise.

To move backward through the recording, turn the scroll dial counterclockwise.

Time 0.0 (T) is the point in the recording at which the data were captured (trigger pressed).

A minus sign (-) in front of a number designates it as the time before capture.

The PIDs being viewed are displayed across the top of the screen with their respective values underneath them.

Review of the captured data is controlled by the specific functions displayed above the corresponding numerickeypad button.

– INFO - The INFO button will display the information screen. This screen contains information about therecording, such as recording area, vehicle, type of link, TRIGGER point, type of module, and recordingsize.

– REW - The REW button will move backward through the recording at fast speed.

– STOP - The STOP button will stop the playback of the recording.

– PLAY - The PLAY button will move forward through the recording at normal speed.

– FWD - The FWD button will fast-forward the recording.

NGS PID Viewing Options

BF 5-11

NGS APPENDIX


NGS PID Viewing Options (continued)

GRAPH DISPLAY:

The graphing capability of NGS allows you to make visual comparisons between closely related PIDs so that

you may determine whether or not their interaction is correct. It also allows you to see a “glitch” that is not

obvious on the table format.

Just as with the table display, up to four PIDs can be selected for graphing, but only two at a time can bedisplayed.

When the graph display appears on the screen, the names of the two currently selected PIDs will appear - oneon the right and one on the left.

If more than two PIDs have been selected for viewing, you can change what is displayed on the screen by usingthe numeric keypad.

To change the left-hand PID, push number 2 on the numeric keypad. To change the right-hand PID, push thenumber 9 on the numeric keypad.

The graph display screen will display a section of the recording that represents a portion of the recording. ThePIDs currently being viewed are displayed to the left and right sides of the screen.

There will be three sets of numbers also located to the left and/or right side of the screen. These numbers referto the following:

– The top number represents the value of the PID at the beginning of the recording.

– The middle number shows the value of the PID where the vertical cursor is positioned.

– The bottom number represents the value of the PID at the end of the graph.

– To move the vertical cursor to the left, turn the scroll dial counterclockwise or clockwise.

The following functions are displayed on the screen just below the graph:

– The - Time button (3) will move the screen toward the beginning of the recording.

– The + Time button (8) will move the screen toward the end of the recording.

NGS Graph Display

BF 5-12

GLOSSARY

1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel Vehicles Glossary - 1March, 2004

GLOSSARY

The following is a list of terms and acronyms used throughout this book.

AFCM Alternative Fuel Control Module

AFS Alternative Fuel System

AFV Alternative Fuel VehicleAUX Auxiliary

B+ Battery Voltage

BARO Barometric SensorBASE VEHICLE The gasoline operating system of the vehicle.

BAUD-RATE Baud-rate refers to how many bits per second we can send over a connection.

BI-FUEL VEHICLE A vehicle that can operate on two different types of fuel (LPG and gasoline).

BFIM Bi-Fuel Injector Module (previous term used for Multiport Injection Vehicles)

BIT Binary Digit. The NGS uses BIT to describe the amount of information it canprocess at one time.

CAUSE PID that indicates reason vehicle changes fuel operating mode (LPG to GASor Gas to LPG)

CFH Cubic Foot per Hour

CHT Cylinder Head Temperature

CGA Canadian Gas Association

CLCF Closed Loop Correction Factor (1998 and earlier MY)

CL_COR Closed Loop Correction Factor (1999 and later MY)

CLEAN AIR ACT The clean air act requires the installation of more advanced pollution controlequipment and changes to industrial operations and even community life-stylethat will lead to reductions in emissions of air pollutants.

CNG Compressed Natural Gas

COM Common

COMPUVALVE The compuvalve uses preprogrammed strategies to control operation of thealternative fuel system on a bi-fuel vehicle. It then meters fuel flow going intothe engine.

CSH Cold Start Heater

DATA BUS The wire(s) that run between control modules over which the modulescommunicate.

DEDICATED VEHICLE A dedicated vehicle uses only CNG for fuel.

DLC Data Link Connector

DTC Diagnostic Trouble Code

DVOM Digital Voltage and Ohm Meter

GLOSSARY

Glossary - 2 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel Vehicles March, 2004

ECT Engine Coolant Temperature

EEC-V Electronic Engine Control Version 5

EFT Engine Fuel Temperature

EGR Exhaust Gas Recirculation

ENERGY POLICY ACT The energy policy act provides for improved energy efficiency. It includesprovisions to allow for greater competition in energy sales.

ETHYL MERCAPTAN A scent that is added to LPG for safety and leak detection.

EVTM Electrical Vacuum Troubleshooting Manual

FORD TECHNICALSERVICE HOTLINE 1-800-826-4694

FAP Fuel Absolute Pressure (98 and earlier MY)

FRPREAB Fuel Absolute Pressure (99 and later MY)FRTMPAB Engine Fuel Temperature Bank 1FTTMP Signal Recieved from the Fuel Tank Temperature SensorFCV Fuel Control Valve

FRP Fuel Rail Pressure

FRT Fuel Rail Temperature

FRPBREAB Fuel Absolute Pressure (99 and later MY)

FSP Fuel Storage Pressure

FTP Fuel Tank Pressure

FTT Fuel Tank Temperature

FUEL_MODE Fuel Operating Mode (CNG or GAS)

GFI Gaseous Fuel Injection

HD5 Ford requires the LPG fuel used in there systems to meet HD5 standards.HD5 limits the amount of propene (a different type of gas than propane) thatmay be in the LPG mixture. Too much propene can lead to plastic-like depositsto form in the fuel system.

HD10 In California Ford requires the LPG fuel used in there systems to meet HD10standards. The difference between HD10 and HD5 is the amount of propene(a different type of gas than propane) that may be in the LPG mixture. Toomuch propene can lead to plastic-like deposits to form in the fuel system.

HO2S Heated Oxygen Sensor

IAT Intake Air Temperature

KOEO Key On Engine Off

KOER Key On Engine Running

KPA KiloPascals Absolute

LCD Liquid Crystal Display

GLOSSARY (continued)

GLOSSARY

1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel Vehicles Glossary - 3March, 2004

LED Light Emitting Diode

LPG Liquefied Petroleum

MAF Mass Air Flow

MAP Manifold Absolute Pressure

MIL Malfunction Indicator Lamp

MULTIPLEXING A computer strategy that allows module-to-module communication duringnormal vehicle operation.

NFPA National Fire Protection Association

NGS New Generation STAR

OBD On-board Diagnostics

OPMODE Operating Mode

PC/ED Powertrain Control/Emission Diagnosis

PCM Powertrain Control Module

PCV Pressure Control Valve

PD Preliminary Diagnostics

PID Parameter Identification

PROTOCOL A computer language that allows communication between control modules.

PSI Pounds per Square Inch

PWM Pulse Width Modulated

RCV Regulator Control Valve

RPM Revolutions Per Minute

SELSW Fuel Selector Switch Position

SIG Signal

SIG RTN Signal Return

SPDT Single Pole Double Throw

SSCC Symptom-to-System-to-Component-to-Cause

STOICHIOMETRIC Ideal air/fuel ratio.

SW B+ Switched Battery Voltage

TPS Throttle Position Sensor

TSB Technical Service Bulletin

VCL Vehicle Communications Link

VECI Vehicle Emissions Control Information

VIN Vehicle Identification Number

VSS Vehicle Speed Sensor

WOT Wide Open Throttle

GLOSSARY (continued)

GLOSSARY

Glossary - 4 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel Vehicles March, 2004

NOTES

TOOL LIST

1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles

ROTUNDA TOOL LIST AND ORDER FORM

The tools listed below were used during the presentation of this course. It is essential that correcttools be used during transmission service and repair. For your convenience, the tools are listed belowand a Rotunda Order Form can be found on the following pages.

New Generation STAR (NGS) Tester 007-00500

Digital Multimeter 007-00001

104-pin Breakout Box 014-00950

Spring Lock Coupling Disconnect Tools D87L-9280-A

Spring Lock Coupling Disconnect Tool D87L-9280-B

Spring Lock Coupling Disconnect Tool T83P-19326-C

Contour Vent Kit 164-R0911

Rotunda Natural Gas Service Kit 134-00254 (Contents include the following:)– Manual Override Tool 134-00050– Fuel Fill Valve Filter Remover/Installer Tool 134-00115– Fuel Rail Pressure Test & Venting Kit 134-00116– Fuel Filler Neck Venting Tool 134-00117– Venting Hose 134-00118– Electronic Fuel Injector Tester 134-00119– Electrical Harness for Venting Tanks 134-00120– Grounding Cable 134-00121– Vent Box - Pressure Test Adapter 134-00122– Electronic Leak Detector 134-00049– E&F Series CNG Venting Adapter 134-00225

Rotunda Gaseous Fuel Service Kit 164-R0912 (Contents include the following:)– NGS Tester Program Card 164-R0905– NGS Tester Adapter Cable 164-R0906– Fuel Pressure Sensor R&I Tool 164-R0906– Tank Valve Wrench 164-R0908– Tank Solenoid Ring Wrench 164-R0909– Tank Solenoid Valve Core Wrench 164-R0910– Venting Kit 164-R0911

1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles

TOOL LIST

OR

DE

R FO

RM

PA

RT I

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Buyer, having been quoted both an installm

ent Price and a lesser Cash Price, hereby purchases from

Seller on installment price basis, upon the term

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rees to paySeller th

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:

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❏ 30 D

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❏ 12 M

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24 Mo. (M

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❏ 36 M

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48 Mo. (M

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❏ 90 D

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Notice To Bu

yer:1.

Do not sign this contract before you read it or if it contains any blank spaces.

2.You are entitled to an exact copy of the contract you sign.

3.U

nder the law you have the right to pay off in advance the full am

ount due and under certaincircum

stances to obtain partial refund of the time charge.

BUYER A

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September 1999

315-195Prices su

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chan

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1. P

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Term

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If Buyer h

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If Buyer h

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2. Title. Title to Equ

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Seller shall pass to Bu

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es that: (a) Bu

yer has

selected Equipm

ent an

d Man

ufactu

rer, and Bu

yer has determ

ined Equ

ipmen

t’s suit-

ability and fitn

ess for the Bu

yer’s purpose, (b) Seller is n

ot the m

anu

facturer of Equ

ip-m

ent, an

d (c) M

anu

facturer issu

es its ow

n w

arranty an

d p

erform

s the o

blig

ation

su

nd

er such

warran

ty.

7. W

arranty. TH

E MA

NU

FAC

TURER’S W

ARRA

NTY SH

ALL BE BU

YER’S EXCLU

SIVE REM

EDY,

RECO

URSE O

R DA

MA

GE FO

R AN

Y DEFEC

T IN W

ORKM

AN

SHIP O

R MA

TERIAL O

R AN

YFA

ILURE O

F THE EQ

UIPM

ENT. SELLER M

AKES N

O W

ARRA

NTIES, REPRESEN

TATIO

NS,

IND

EMN

ITIES OR G

UA

RAN

TEES WH

ATSO

EVER W

ITH RESPEC

T TO EQ

UIPM

ENT EI-

THER EXPRESS O

R IMPLIED

, ARISIN

G BY LA

W O

R CU

STOM

, INC

LUD

ING

AN

Y IMPLIED

WA

RRAN

TY OR M

ERCH

AN

TABILITY O

R FITNESS FO

R A PA

RTICU

LAR PU

RPOSE. TH

ELIA

BILITY OF TH

E SELLER SHA

LL BE LIMITED

TO EXPRESS O

BLIGA

TION

TO D

ELIVER

THE EQ

UIPM

ENT. U

ND

ER NO

CIRC

UM

STAN

CES SH

ALL SELLER BE LIA

BLE OR RE-

SPON

SIBLE FOR A

NY SPEC

IAL, IN

DIREC

T, INC

IDEN

TAL, C

ON

SEQU

ENTIA

L OR PU

NI-

TIVE D

AM

AG

ES, WH

ETHER FO

RESEEABLE O

R UN

FORESEEA

BLE, WH

ICH

BUYER M

AY

INC

UR, EX

PERIENC

E OR C

LAIM

, INC

LUD

ING

, BUT N

OT LIM

ITED TO

, CLA

IMS FO

RLO

SS OF PRO

FITS, INTERRU

PTION

IN BU

SINESS, LO

ST OPPO

RTUN

ITY, WO

RK STOP-

PAG

E OR O

THER IM

PAIRM

ENT O

F ASSETS, A

RISING

OU

T OF M

ISREPRESENTA

TION

,N

EGLIG

ENC

E, STRICT LIA

BILITY, IN TO

RT OR O

THERW

ISE, ON

AC

CO

UN

T OF EN

TER-IN

G IN

TO O

R RELYING

ON

THIS A

GREEM

ENT, EV

EN IF SELLER H

AS BEEN

AD

VISED

OF

THE PO

SSIBILITY OF SU

CH

DA

MA

GES.

8. Freig

ht an

d T

axes. Freigh

t costs and applicable taxes w

ill be added to the fin

al invoice

and

will b

e bo

rne b

y Buyer.

9. Se

curity In

tere

st. Bu

yer hereb

y gran

ts to Seller a co

ntin

uin

g secu

rity interest in

the

Equipm

ent, in

cludin

g all produ

cts and proceeds th

ereof, un

til all amou

nts du

e here-

un

der are paid. Buyer ag

rees to execute, an

d pay filing

fees for, any fin

ancin

g state-

men

t or o

ther d

ocu

men

ts deem

ed n

ecessary by Seller to

main

tain a valid

security

interest in

the Equ

ipmen

t.

10

. Main

tenan

ce. Buyer sh

all use th

e Equipm

ent carefu

lly and properly. Bu

yer, at Buyer’s

own

expense, sh

all main

tain an

d repair all items of th

e Equipm

ent in

order to keepth

em in

go

od

ord

er and

con

ditio

n an

d, in

particu

lar, shall co

mp

ly fully w

ith th

em

ainten

ance, operatin

g, u

sage or oth

er instru

ctions provided b

y the m

anu

facturer.

Buyer au

thorizes Seller, or an

y third party appoin

ted by Seller, to inspect th

e Equip-

men

t wh

en n

ecessary. Buyer sh

all at all times keep th

e Equipm

ent free an

d clear of alllien

s, charg

es or en

cum

bran

ces.

11

. Perso

nal P

rop

erty. Ford proprietary diagn

ostic equipm

ent (in

cludin

g th

e software, if

applicable) sh

all be kept at Bu

yer’s premises as listed

on

the reverse sid

e and

shall

remain

personal property reg

ardless of how

and to w

hat deg

ree it may be affixed or

attached to an

y buildin

g or stru

cture or w

hat m

ay be the con

sequen

ce of its removal

from

such

bu

ildin

g o

r structu

re. Buyer sh

all no

t encu

mb

er the Equ

ipmen

t (inclu

d-

ing

software, if applicab

le) un

til all amou

nts ow

ing

to Seller hereu

nd

er are paid. In

addition, Seller g

rants to Bu

yer, and Bu

yer accepts, a non

-exclusive licen

se to use th

eEqu

ipmen

t (inclu

ding

the softw

are, if applicable) in accordan

ce with

the term

s and

con

ditio

ns set fo

rth h

erein. Th

e license (an

d Equ

ipm

ent) sh

all no

t be leased

, sold

,assig

ned or oth

erwise tran

sferred, in w

hole or in

part. In th

e event, Bu

yer proposesto lease, sell assig

n or oth

erwise tran

sfer the Equ

ipmen

t (and/or its softw

are, if appli-cable), in

wh

ole or in part, to an

y person or en

tity, Ford Motor C

ompan

y shall h

avea Rig

ht of First Refu

sal to purch

ase the Equ

ipmen

t (inclu

ding

all software, if applicable)

for Ten an

d 00/100 Dollars ($10.00) in

U.S. cu

rrency.

12

. Insu

ran

ce an

d In

dem

nifica

tion

. Buyer sh

all defen

d, in

dem

nify an

d h

old

harm

lessSeller from

and

again

st, and

at Buyer’s ow

n expen

se provide in

suran

ce satisfactoryto Seller coverin

g an

y and

all losses, dam

ages, claim

s, expenses an

d oth

er liabilities

(inclu

din

g atto

rney’s fees,) relatin

g to

or arisin

g o

ut o

f: (I) dam

age, lo

ss, theft, o

rd

estructio

n o

f the Equ

ipm

ent, o

r (ii) death

, inju

ry or p

rop

erty dam

age co

nn

ectedw

ith th

e use, o

peration

or co

nd

ition

(inclu

din

g w

itho

ut lim

itation

, defects w

heth

eror n

ot discoverable by any party) of th

e Equipm

ent. Bu

yer shall prom

ptly notify Seller

of any su

ch claim

. Seller shall h

ave the rig

ht to participate, at its ow

n expen

se, in an

yproceedin

g for w

hich

Buyer h

as un

dertaken th

e defense of Seller, an

d in n

o event

shall Bu

yer settle any claim

again

st Seller with

out Seller’s prior w

ritten con

sent, Bu

yersh

all provide evidence of su

ch in

suran

ce to Seller upon

deman

d. Seller is un

der no

ob

ligatio

n to

examin

e any in

suran

ce certificate or ad

vise Bu

yer that its in

suran

cedoes n

ot comply w

ith th

e requirem

ents set forth

herein

. The losses covered by in

sur-

ance sh

all in all cases be payable to Seller an

d Buyer as th

eir interests m

ay appear. IfBu

yer fails to in

sure th

e Equip

men

t as herein

pro

vided

, Seller may, b

ut is n

ot o

bli-

gated to, place su

ch in

suran

ce upon

the Equ

ipmen

t and th

e Buyer ag

rees to pay toSeller o

n d

eman

d th

e prem

ium

s for su

ch in

suran

ce placed

by Seller. In

no

event

shall an

y insu

rance co

verage b

e deem

ed to

limit o

r replace B

uyer’s o

blig

ation

toin

dem

nify Seller as p

rovid

ed h

erein.

13

. Defau

lt. In th

e event th

at Buyer: (a) fails to pay an

y amou

nt du

e hereu

nder w

ithin

ten(10) days of th

e due date, (b) fails to com

ply with

any oth

er provision h

ereof, (c) files,or if th

ere is filed again

st Buyer, an

y petition u

nder an

y bankru

ptcy or insolven

cy laws

or su

ffers the ap

po

intm

ent o

f any tru

stee or receiver fo

r all or an

y part o

f Buyer’s

bu

siness o

r assets, or (d

) has an

y assign

men

t (volu

ntarily o

r invo

lun

tarily), lien,

attachm

ent or levy issu

ed again

st the Equ

ipmen

t (un

less such

petition, assig

nm

ent or

app

oin

tmen

t, lien, attach

men

t or levy is w

ithd

rawn

or n

ullified

with

in tw

enty (20)

days) then

Buyer sh

all be in defau

lt hereu

nder an

d all of Buyer’s in

debtedness an

do

blig

ation

s to Seller sh

all, at Seller’s optio

n, b

ecom

e imm

ediately d

ue an

d payab

le,an

d Seller may, at its option

, termin

ate this con

tract and repossess an

y and all item

sof Equ

ipmen

t with

or with

out leg

al process and sell th

e same at private or pu

blic salew

ithou

t prior notice to Bu

yer to the exten

t permitted by law

. Upon

request, Bu

yer shall

deliver the Equ

ipmen

t to Seller at a place design

ated by Seller. Repossession an

d/orsales of th

e Equipm

ent u

pon su

ch defau

lt shall n

ot affect the Seller’s rig

ht to retain

allpaym

ents m

ade prior to repossession or to recover th

e balance du

e hereu

nder for

any d

eficiency. Bu

yer shall reim

bu

rse Seller all costs o

f collectio

n, repo

ssession

and

resale (inclu

ding

reasonable attorn

eys’ fees, court costs an

d other expen

ses incu

rredb

y Seller.) Buyer h

ereby releases Seller from

any liab

ility for damag

es resultin

g from

repo

ssession

hereu

nd

er. The rig

hts an

d rem

edies o

f Seller, in th

e event o

f defau

lth

erein m

entio

ned

shall n

ot b

e deem

ed exclu

sive bu

t shall b

e cum

ulative an

d in

add

ition to all oth

er righ

ts and

remed

ies existing

un

der law

, and

may b

e enforced

successively or con

curren

tly. Waiver by Seller of an

y default sh

all not be deem

ed aw

aiver of an

y oth

er defau

lt.

14

. Gen

eral. The w

aiver by either party of, or failu

re to claim, a breach

of any provision

ofth

is contract sh

all not be deem

ed to be a waiver of an

y provision of th

is contract, sh

alln

ot be deemed to be a w

aiver of any su

bsequen

t breach or to affect in

any w

ay the

effectiveness o

f such

pro

vision

. This co

ntract co

nstitu

tes the en

tire agreem

ent b

e-tw

een th

e parties and m

ay not be ch

ang

ed except by an in

strum

ent in

writin

g sig

ned

by the party to be ch

arged. Th

is contract m

ay not be assig

ned by Bu

yer with

out th

eSeller’s prior w

ritten con

sent. Seller m

ay assign

this con

tract at any tim

e but sh

all not

thereb

y be relieved

from

any liab

ility hereu

nd

er. In th

e event th

at on

e or m

ore

clauses of th

is contract are fou

nd

to be u

nen

forceable, illeg

al or contrary to pu

blic

policy by court of com

petent ju

risdiction, th

e remain

der of this con

tract shall rem

ainin

full force an

d effect except for the u

nen

forceable, illegal or oth

er provisions. Th

isag

reemen

t is a Mich

igan

agreem

ent an

d sh

all be in

terpreted

, con

strued

and

en-

forced in accordan

ce with

the law

s of the State of M

ichig

an, U

nited States of A

merica.

Each of th

e parties here to ag

rees that an

y legal or equ

itable action or proceedin

gw

ith resp

ect to th

is agreem

ent sh

all be b

rou

gh

t on

ly in an

y cou

rt of th

e State of

Mich

igan

, or in

any co

urt o

f the U

nited

States of A

merica sittin

g in

Mich

igan

, and

each of th

e parties hereto su

bmits to an

d accepts gen

erally and u

ncon

ditionally th

eju

risdictio

n o

f tho

se cou

rts with

respect to su

ch party’s perso

n an

d pro

perty. Eachp

arty hereb

y irrevocab

ly waives an

y ob

jection

to th

e laying

of ven

ue o

f any su

chactio

n o

r pro

ceedin

g in

the ab

ove d

escribed

cou

rts.

15

. Finan

ce Ch

arge. M

onth

ly portion of Fin

ance C

harg

e (Part III, Item 3) du

e is calculated

each m

onth

by mu

ltiplying

1/12 of the an

nu

al finan

ce charg

e rate times th

e remain

-in

g portion

of the U

npaid Balan

ce of Cash

Price, and is added to th

e portion of th

eU

npaid

Balance of C

ash Price d

ue each

mon

th.

PA

RT III

TER

MS &

CO

ND

ITION

S

Installm

ent P

lan A

greem

ent

1.C

ash Price

$

2.D

own

Paymen

t (if any)

$

3.U

npaid

Balance of C

ash Price

$(D

ifference between 1 and 2)

4.Fin

ance C

harg

e$

(Finance charg

e will reduce each

month

)C

all 1-800-768-8632 for the current finance charge rate.

5.Tim

e Balance (3 + 4)

$

6.N

um

ber o

f Installm

ents

❏ 12

❏ 24

❏ 36

❏ 48

❏ 60

equal mon

thly in

stallmen

ts. Taxes and

transportation (if any) will be billed separately.

7.In

stallmen

t Paymen

t Price (1 + 4)$

I agree to pay th

e time Balan

ce set forth in

accordance w

ith th

e abovesch

edu

le and

the term

s and

con

ditio

ns o

f this o

rder fo

rm.

Dealer Sig

natu

re: D

ate:

MA

IL CO

MPLETED

ORD

ER FORM

TO:

ROTU

ND

A EQ

UIPM

ENT PRO

GRA

MP.O

. Box 1450Ken

osha, W

I 53141

September 1999

315-195Prices su

bject to

chan

ge w

itho

ut n

otice

Documents

Crownvic Manual