2004 FORD E SERIES engine

E-450 Cutaway
1.Fuel rail sensors -An injection pressure sensor and an engine fuel
temperature sensor provide engine fuel information to the powertrain
control module.
2.Isolation solenoid valve -Blocks fuel flow from supply line to
injection manifold when the engine is off.
3.Engine -
A modified 5.4L gasoline engine with Sequential Electronic Fuel
Injection (SEFI), an improved valvetrain and a high compression ratio.
4.Powertrain control module -Uniquely calibrated for NGV application.
5.Extended range fuel tank -An optional steel fuel tank located in
the cargo area.
6.Sealed vent box -Dispenses natural gas vapor to atmosphere if
vapor becomes present.
7.Internal tank valve -One electronically actuated, normally closed
solenoid valve is located in each fuel tank. The valve is wired into the
vehicle’s inertia switch. If the engine cranks but does not start after a
collision, the fuel solenoid valve inertia switch may have been activated.
The inertia switch is a device intended to close the fuel solenoid valve
when your vehicle has been involved in a substantial jolt.
8.Stone shield(s) -Protective shield(s) to prevent damage to the fuel
tank(s) caused by road debris or other road hazards.
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9.Aft axle fuel tanks -Two steel fuel tanks located behind the rear axle.
10.Midship fuel tank -A steel fuel tank located underbody.
11.High pressure fuel lines -Delivers high pressure fuel to the fuel
tanks and fuel pressure regulator.
12.Fuel pressure regulator/Coalescent fuel filter -Reduces fuel
pressure and removes impurities from the gas.
13.Low pressure fuel line -Supplies natural gas to the injectors.
14.AFV module -Contains the unique powertrain electronics that are
required for an NGV.
F-150 Heritage Pick-up
1.Fuel rail sensors -An injection pressure sensor and an engine fuel
temperature sensor provide engine fuel information to the powertrain
control module.
2.Isolation solenoid valve -Blocks flow from supply line to injection
manifold when the engine is off.
3.Engine -
A modified 5.4L gasoline engine with Sequential Electronic Fuel
Injection (SEFI), an improved valvetrain and a high compression ratio.
4.Powertrain control module -Uniquely calibrated for NGV application.
5.Internal tank valve -One electronically actuated, normally closed
solenoid valve is located in each fuel tank. The valve is wired into the
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vehicle’s inertia switch. If the engine cranks but does not start after a
collision, the fuel solenoid valve inertia switch may have been activated.
The inertia switch is a device intended to close the fuel solenoid valve
when your vehicle has been involved in a substantial jolt.
6.Standard fuel tanks -Two steel fuel tanks located in the bed of the
truck.
6b.In-bed tank cover -Cover to prevent damage to the fuel tanks.
Protective shield to prevent damage to the fuel tank caused by road
debris or other road hazards.Do not sit, stand or place heavy loads
on the fuel tank cover.
7.Stone shield -Protective shield to prevent damage to the fuel tank
caused by road debris or other road hazards.
8.Underbody fuel tank -A steel fuel tank located underbody.
9.High pressure fuel lines -Delivers high pressure fuel to the fuel
tanks and fuel pressure regulator.
10.Fuel pressure regulator/Coalescent fuel filter -Reduces fuel
pressure and removes impurities from the gas.
11.Low pressure fuel line -Supplies natural gas to the injectors.
12.AFV module -Contains the unique powertrain electronics that are
required for an NGV.
Crown Victoria
1.NGV module -Provides power for the fuel injectors. Also, drives the
fuel gauge using fuel tank pressure and temperature sensors.
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2.Isolation solenoid valve -Blocks flow from the injection manifold
when the engine is off.
3.Engine -Is a modified 4.6L engine with Sequential Electronic Fuel
Injection (SEFI) and increased compression ratio.
4.Engine coolant lines -Provide required heat to high pressure
regulator.
5.Powertrain control module -Required for NGV application.
6.Sealed vent box -Vented to underbody. Dispenses natural gas vapor
to atmosphere if vapor becomes present.
7.Tank pressure sensor -Fuel tank pressure sensor located in this
tank’s solenoid valve is used for fuel indication.
8.Solenoid tank valves -One solenoid per tank. Internal valves with
shut-off solenoids wired into inertia circuit for crash protection.
9.Two fuel tanks -Located in the trunk. On taxi or police vehicles, an
extended range fuel system is available which includes one additional NG
fuel tank mounted in the trunk (total of three).
10.Fueling point -Fueling receptacle is conveniently located with the
fuel door. Same location as gasoline fueled vehicles.
11.Tank shield-Protective shield able to prevent damage to the fuel
tanks caused by trunk cargo.
12.Tank temperature sensors -One each in set of tanks (solenoid
valves) used for fuel indication.
13.Optional fuel tank -A fiber-wrapped steel fuel tank (total of three
tanks in the trunk). Also has a sealed vent box which vents to the
underbody. Dispenses natural gas vapor to the atmosphere if vapor is
present.
14.Two fuel tanks -Located underbody to facilitate fuel system design.
15.Stone and heat shield -Protective shield able to prevent damage to
the fuel tanks caused by road debris or other road hazards.
16.High pressure fuel lines -Delivers high pressure fuel to the
pressure regulator.
17.Pressure regulator and coalescent fuel filter assembly -
Reduces the fuel pressure to the fuel injector.
18.Low pressure fuel lines -Supplies natural gas to the engine.
19.Fuel rail sensors -One injection pressure sensor and one engine
fuel temperature sensor provide engine fuel information to the PCM.
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ADAPTERS
DO NOTuse fuel receptacle adapters when refueling your vehicle.
The profiles of both the natural gas vehicle receptacle and the fuel
station nozzles are specified by ANSI/AGA NGV1-1994, CGA NGV1-M94.
These profiles are specified for compressed natural gas vehicles and fuel
stations for safety purposes. Three separate adapter profiles are
available. P24, P30 and P36 respectively, are specified for the three
different service pressures of 16,500 kPa (2,400 psi), 20,700 kPa
(3,000 psi) and 24,800 kPa (3,600 psi).
Your vehicle’s service pressure may be 20,700 kPa (3,000 psi) or 24,800 kPa
(3,600 psi), depending upon application. Refer to the label on the fuel filler
door:
• If your vehicle’s fuel system is rated at 20,700 kPa (3,000 psi), it can
be refueled using a P30 or P24 nozzle. However, use of a P24 nozzle
will result in an incomplete fill.
• If your vehicle’s fuel system is rated at 24,800 kPa (3,600 psi), it can
be refueled using a P36, P30 or P24 nozzle. However, use of a P30 or
P24 nozzle will result in an incomplete fill.
DO NOT over pressurize the CNG fuel system or damage to the
fuel system and possible personal injury may occur.
NATURAL GAS DISPENSING
Do not use liquefied natural gas (LNG) or a CNG that is derived
from a process such as flashing (heating LNG). Failure to use the
correct type of fuel may cause damage to the engine and fuel
system components.
Most dispensers have a digital indicator displaying the cost and amount
of fuel delivered to your vehicle. Fuel delivery to the vehicle is stopped
when the pressure of fuel stored on the vehicle equalizes with the
temperature compensated pressure of fuel stored at the station. As the
pressure between the station and vehicle equalizes, the cost and quantity
meters slow to a near stop. When this occurs, refueling is complete.
Certain noises can be expected during the refueling process and may
vary depending on the type of fuel station and your proximity to the fuel
compression and storage equipment. At the beginning of refueling you
might hear the rushing noise of gas entering the vehicle through the
station hose and tubing. At the end of refueling, the fuel receptacle on
the vehicle may make a high pitch noise or chatter. This is another
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indication that refueling is nearly complete. Also, the station compression
equipment may turn on at any time during the refueling process.
FUEL QUALITY
Do not use liquefied natural gas (LNG) or a CNG that is derived
from a process such as flashing (heating LNG). Failure to use the
correct type of fuel may cause damage to the engine and fuel
system components.
Use only a CNG fuel that meets the specification of NFPA-52 and SAE
J1616 in your NGV. Specifications NFPA-52 and SAE J1616 place limits
on particulate contamination, oil contamination and moisture content to
ensure a quality CNG fuel.
The use of a CNG fuel that does not meet specifications NFPA-52 and
SAE J1616 isnot recommended and may cause engine damage.
Use of poor quality CNG fuel may result in:
• component failure.
• leakage from the fueling point.
• poor vehicle operation.
Use of poor quality fuel may also result in your warranty being
invalidated.
Icing while fueling your vehicle
An icing condition may occur after fueling your vehicle. This may be due
to changes in fuel moisture content, quite often seen during change of
seasons. This condition causes your vehicle ’s fuel fill valve to remain
slightly open, allowing some natural gas to be released.
Breathing hydrocarbon gases (CNG) or air which lacks oxygen
due to the presence of hydrocarbon gases can result in
headache, dizziness and weakness in the arms and legs. In the event of
illness due to inhaling hydrocarbon gases, immediately move the victim
to fresh air and contact medical emergency personnel.
The icing condition may be observed when disconnecting the fuel
dispenser ’s fill nozzle from your vehicle. You may notice more gas than
normal venting from the vehicle fill valve through the vent hose to the
dispenser. If this occurs, keep the fill nozzle connected (or reconnect it)
and wait about 30 seconds. This will allow the ice to melt. Repeat this
procedure as necessary. When normal fuel venting occurs, remove the fill
nozzle and stow it as instructed on the dispenser.
Do not fuel your vehicle with the ignition in the ON position; doing so
may increase the amount of fuel venting during this icing condition.
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SERVICING YOUR NATURAL GAS VEHICLE
Service to the CNG fuel system should be conducted at a
qualified dealership by a trained NGV technician only. Failure to
do so may cause damage to components or cause bodily harm.
FUELING
Do not fuel your vehicle with the ignition on the ON position. Failure to
do so may cause component damage.
Fueling a NGV, with a few exceptions, is very similar to fueling a gasoline
vehicle. The same care and cautions used when fueling a gasoline vehicle
should be exercised when fueling a NGV. In particular, for safety reasons,
an enginemustalways be turned off when refueling is occurring. Always
use the recommended fill nozzle to refuel your vehicle.
The fueling point, or fuel receptacle is located near the driver’s side.
When refueling, the enginemustbe shut off.
Two methods for filling the fuel tanks are available to NGV owners. The
fast-fill method, described below, is available at many of the commercial
and privately owned filling stations. The slow-fill method, also described
below, is available for purchase or lease from a number of commercial or
natural gas utility companies.
Fast fill procedure
“Fast-filling”a NGV involves rapidly (typical fill time: 3–5 minutes)
raising the pressure in the vehicle’s tanks by“fast-fill”refueling station.
“Fast-filling”a vehicle provides the greatest convenience to the driver in
terms of time spent refueling. However, present“fast-fill”refueling
technology does not presently allow a NGV to be completely refueled to
its maximum rated capacity. Therefore,“fast-filling”results in a reduced
driving range and an initial fuel gauge reading of Full. However, within
approximately 10 minutes, the fuel gauge of a NGV that has been
“fast-filled”will drop about
1⁄8th of a tank lower to reflect the reduced
amount of fuel that was actually added.
Slow fill procedure
“Slow-filling” a NGV involves slowly raising the pressure in the vehicle’s
fuel tank(s) by a slow fill station (typical fill rate: 6-8 hours).
“Slow-filling” usually is done overnight and allows the greatest amount of
fuel to be added to a NGV. A properly functioning “slow-fill” refueling
station will fill the NGV’s fuel tank(s) to a fuel gauge reading of “full” at
a temperature of 21°C (70°F).
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Use caution when fueling your vehicle. Make sure the engine is
turned off and all flammable material is extinguished. Observe all
Dispensing Equipment Safety Standards and Operating Procedures.
The procedure is the same for both fast-fill and slow-fill fueling.
1. Open fuel door and determine the pressure rating of your vehicle’s
fuel system.
2. Remove protective cap from the vehicle’s fuel receptacle. Remove any
debris that may be present.
3. Follow the natural gas fueling procedures provided by the natural gas
dealer and dispense the CNG until the fuel tanks are full or until the flow
stops.
4. When refueling is complete, follow the natural gas dispensing
equipment’s operating procedures to shut the natural gas flow off.
5. Remove the dispensing connector and put protective cap on the
vehicle’s fuel receptacle. Close the fuel door.
Refill capacities — BTU equivalent to gasoline
E-Series (3000 psi)
Fueling method Standard tank With extended range tank
Slow-fill 60.9L (16.1 gallons) 92.7L (24.5 gallons)
Fast-fill 51.8L (13.7 gallons) 78.7L (20.8 gallons)
E-Series (3600 psi)
Fueling method Standard tank With extended range tank
Slow-fill 70.0L (18.5 gallons) 106.0L (28.0 gallons)
Fast-fill 59.4L (15.7 gallons) 90.1L (23.8 gallons)
E-Series Cutaway 158” Wheelbase (3000 psi)
Fueling
methodStandard
tanksWith Extended
Range - One
In-body TankWith Extended
Range - Two
In-body Tanks
Slow-fill 55.3L
(14.6 gallons)84.0L
(22.2 gallons)112.4L
(29.7 gallons)
Fast-fill 46.9L
(12.4 gallons)71.2L
(18.8 gallons)95.8L
(25.3 gallons)
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