2004 FORD E SERIES fuel cap

COMPRESSED NATURAL GAS (CNG) FUEL SYSTEM
Your vehicle is equipped with a dedicated compressed natural gas (CNG)
fuel system that is under high pressure.
Depending upon the application, the CNG fuel system is rated at a pressure
of 20,700 kPa (3,000 psi) at 21°C (70°F) or 24,800 kPa (3,600 psi) at
21°C (70°F). Refer to the label on the fuel filler door to determine the
fuel system pressure rating.
Use caution when servicing or maintaining any of the components of the
CNG fuel system.
Service to high-pressure fuel system components must be
conducted only at qualified dealerships by qualified technicians.
Failure to do so may cause damage to components or cause bodily
harm.
On F-150 Heritage natural gas vehicles,do not modify or replace the
bed with any non-OEM components. Should the bed need to be removed
for service or replacement, it should be done by a qualified dealership
using qualified technicians. Do not sit, stand or place heavy loads on the
in-bed or in-vehicle tank covers. Any bed cap added to this vehicle must
be well ventilated. Failure to provide adequate ventilation could result in
gas vapor build up over time potentially resulting in a combustible
mixture.
FUSES/ELECTRICAL SYSTEMS
NGV fuse strategy may be different than a non-NGV. Consult theFuses
and Relayssection in theRoadside emergencieschapter of your
Owner’s Guide for differences.
Introduction
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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).
Servicing your vehicle
12

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)
Servicing your vehicle
13

Crown Victoria (3600 psi)
Fueling method Standard tanks With extended range
system
1
Slow-fill 45.0L (11.9 gallons) 59.1L (15.6 gallons)
Fast-fill 38.2L (10.1 gallons) 50.3L (13.3 gallons)
1Police and Taxi vehicles.
Extended range fuel system
Crown Victoria Police and Taxi vehicles with the extended range fuel
system have a 5–passenger seating configuration with one additional
CNG fuel tank mounted in the luggage compartment.
E-Series vehicles with the extended range fuel system have one
additional CNG fuel tank mounted in the cargo area behind the rear seat.
TRAILER TOWING
On F-150 Heritage models, your NGV has the capability for towing up to
2,267 kg (5,000 lbs.) using the factory installed step-bumper. It is
recommended that the vehicleNOTbe modified for towing (i.e.-any
frame-mounted hitches).
Crown Victoria and E-Series Van/Wagon and Cutaway models are not
equipped with a trailer towing option. It is recommended that the vehicle
NOTbe modified for towing.
TOWING YOUR CNG VEHICLE
Refer to your Owner’s Guide for towing procedure except E-Series
vehicles with the optional tank package whichMUSTbe flat-bed towed.
NGV REFUELING STATIONS
To obtain a directory of all the refueling stations in the United States,
contact the American Gas Association (AGA) at (703) 841–8400 or the
national website: www.afdc.doe.gov/refueling.html. In Canada, contact
Union Gas at 1–800–265–5277.
SERVICING YOUR VEHICLE
The following is a brief description of unique maintenance items for your
NGV. For a complete list of maintenance items and intervals, refer to
yourService Guide.
Tank inspection and replacement
For your protection, the CNG fuel tanks require visual inspection every
three years or 58,000 kilometers (36,000 miles) whichever comes first.
Servicing your vehicle
15