41S01T0 ford dedicated CNG and multiport bi fuel CNG vehicles 1999 2004

Introduce the Ford Alternative FuelCurriculum Administer the prerequisite review Alternative Fuel Vehicle AFV CurriculumFord 1999-2003 Dedicated CNG and MultiportBi-Fuel CNG Vehicle Inst

Dedicated CNG and Multiport Injection Bi-Fuel CNG Vehicles

2-Day Dedicated CNG Vehicles Course Code 41F01T0

2-Day Multiport Injection Bi-Fuel CNG Vehicles Course Code 41F02T0

March, 2004

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 manualprovides 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 tocomplete a particular procedure CAUTIONS are given to prevent you from making an error that coulddamage the vehicle WARNINGS remind you to be especially careful in those areas where carelessnesscan cause personal injury The following list contains some general WARNINGS that you shouldfollow 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 operate

at 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 andsuggestions do not supersede or override the provisions of the Warranty and Policy Manual or theWorkshop 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 thehandbook was approved for printing Ford Motor Company reserves the right to discontinue models at anytime, 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

INTRODUCTION AND PREREQUISITE REVIEW

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

LESSON 1: INTRODUCTION TO CNG VEHICLES

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

LESSON 2A: DEDICATED CNG OPERATION

DEDICATED CNG VEHICLE THEORY OF OPERATION 2 A - 2 CNG FUEL SYSTEM PRESSURES 2 A - 6 ACTIVITY 2A — WORKSHEET A 2 A - 10 ACTIVITY 2A — WORKSHEET B 2 A - 11 ACTIVITY 2A — WORKSHEET C 2 A - 12 ACTIVITY 2A — WORKSHEET D 2 A - 13

LESSON 2B: MULTIPORT BI-FUEL CNG VEHICLE OPERATION

MULTIPORT BI-FUEL CNG VEHICLE THEORY OF OPERATION 2 B - 2 CNG FUEL SYSTEM PRESSURES 2 B - 7 ACTIVITY 2B — WORKSHEET E 2 B - 10 ACTIVITY 2B — WORKSHEET F 2 B - 11 ACTIVITY 2B — WORKSHEET G 2 B - 12 ACTIVITY 2B — WORKSHEET H 2 B - 13 LESSON 3A: DEDICATED CNG COMPONENTS

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

Fuel Filters 3A - 11 High Pressure Regulator 3A - 12 Fuel Injection Supply Manifold 3A - 14 Fuel Injectors 3A - 16 CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DEVICES 3A - 18 Inputs and Outputs Chart 3A - 19 Powertrain Control Module (PCM) 3A - 20 Unique CNG PCM Input Devices 3A - 21 Unique CNG Outputs of the PCM 3A - 22 60-Pin Alternative Fuel Control Module (AFCM) 3A - 23 90-Pin Alternative Fuel Control Module (AFCM) 3A - 24 AFCM Outputs 3A - 25 ACTIVITY 3A — WORKSHEET I 3A - 28 ACTIVITY 3A - WORKSHEET J 3A - 29 ACTIVITY 3A — WORKSHEET K 3A - 30 ACTIVITY 3A — WORKSHEET L 3A - 31

LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS

INTRODUCTION TO MULTIPORT BI-FUEL CNG VEHICLE COMPONENTS 3B - 2 CNG Fuel Fill Valve 3B - 3 Fuel Tanks 3B - 4 Solenoid Tank Valve 3B - 5 CNG Fuel Lines 3B - 7 Coalescent Filter 3B - 9 High Pressure Regulator 3B - 10 CNG Fuel Injection Supply Manifold 3B - 11 Gasoline Fuel Injection Supply Manifold 3B - 12 CNG and Gasoline Fuel Injectors 3B - 13 CNG and Gasoline Fuel Injectors (continued) 3B - 14 CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DEVICES 3B - 15 Inputs and Outputs Chart 3B - 16 Powertrain Control Module (PCM) 3B - 17 Alternative Fuel Control Module (AFCM) 3B - 18 AFCM Input Devices 3B - 19 AFCM Outputs 3B - 23 AFCM Outputs 3B - 24 AFCM Outputs 3B - 25 ACTIVITY 3B — WORKSHEET M 3B - 29 ACTIVITY 3B - WORKSHEET N 3B - 30 ACTIVITY 3B — WORKSHEET O 3B - 31 ACTIVITY 3B — WORKSHEET P 3B - 32

LESSON 4: DIAGNOSIS AND SERVICE

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

Workshop Manual 4 - 11 Wiring Diagrams (EVTMs) 4 - 11 COMPONENT AND SYSTEM TESTING AND SERVICE 4 - 12 Cooling System Pressure Testing 4 - 13 CNG REFUELING PROCEDURES 4 - 14 CNG CONTAMINATION 4 - 16 FUEL FILL VALVE FILTER 4 - 17 COALESCENT FILTER SERVICE 4 - 18 FUEL INJECTOR CLEANING 4 - 19 FUEL TANK REMOVAL 4 - 20 FUEL LINE SERVICE 4 - 21 Fuel System Leak Testing 4 - 22 Crown Victoria Vent Box Leak Test 4 - 24 FUEL SYSTEM VENTING 4 - 25 Solenoid Tank Valve Diagnostics 4 - 27 DEMONSTRATION 1 - CNG VEHICLE DIAGNOSTICS 4 - 29 DEMONSTRATION 1 WORKSHEET 4 - 30 DEMONSTRATION 2 - DEDICATED CNG OR MULTIPORT BI-FUEL CNG VENTING AND SOLENOID DIAGNOSIS 4 - 33 DEMONSTRATION 2 WORKSHEET 4 - 34 ACTIVITY 4 — WORKSHEET Q 4 - 38 ACTIVITY 4 — WORKSHEET R 4 - 40 ACTIVITY 4 — WORKSHEET S 4 - 42 ACTIVITY 4 — WORKSHEET T 4 - 44

APPENDIX 1: COMPRESSED NATURAL GAS SAFETY

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

APPENDIX 2: AFV NEW GENERATION STAR TESTER OPERATION

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

GLOSSARY Glossary - 1 TOOL LIST

ROTUNDA ORDER FORM

Introduce the Ford Alternative Fuel

Curriculum

Administer the prerequisite review

Alternative Fuel Vehicle (AFV) CurriculumFord 1999-2003 Dedicated CNG and MultiportBi-Fuel CNG Vehicle Instructor-Led CourseDescription

Course Terminal ObjectivesAudience

Course PrerequisitesEvaluation

Student GuideService StandardsPrerequisite Review

CONTENTS OBJECTIVES

INTRODUCTION AND PREREQUISITE REVIEW

INTRODUCTION AND PREREQUISITE REVIEW

Courses of the Alternative Fuel Vehicle (AFV) Curriculum

The Alternative Fuel Vehicle (AFV) Curriculum consists of seven courses related to Alternative FuelVehicle (AFV) diagnosis and service With the exception of the Ford Electric Ranger Course, eachcourse 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 properlydiagnose 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

ALTERNATIVE FUEL VEHICLE (AFV) CURRICULUM

Alternative Fuel Vehicle New Generation STAR Web-Based Training - Course CodeWB 31S09W0 (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 - Course Code 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 Code

31F16T0 (Fleet Technicians Only)

Ford Bi-Fuel LPG Vehicle (2-Day) Instructor-Led Training - Course Code 31F17T0 (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 Code

41F01T0 (Fleet Technicians Only)

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

(2-Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles Instructor-Led Course

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 usingthe appropriate tools and equipment

employ appropriate methods and techniques when servicing Dedicated CNG and Multiport Bi-FuelCNG 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 trainingservice technicians of Ford Designated Fleets

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 cians)

Techni-INTRODUCTION AND PREREQUISITE REVIEW

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 Youmust 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”

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)

Repeat vehicle sales

Increased service department utilization

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

INTRODUCTION AND PREREQUISITE REVIEW

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 isdesigned to help you recall the key points and basic concepts of these courses Comprehension of these keypoints 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 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)

INTRODUCTION AND PREREQUISITE REVIEW

13 When servicing a bi-fuel vehicle always retrieve _ first

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?

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 would

accumulate 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

PREREQUISITE REVIEW (continued)

19 If a LPG vehicle is parked in the shop and propane is accidentally released, it would

accumulate 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

PREREQUISITE REVIEW (continued)

INTRODUCTION AND PREREQUISITE REVIEW

NOTES

LESSON 1: INTRODUCTION TO CNG VEHICLES

Upon completion of this lesson the student will

be able to:

– Identify the characteristics of natural

gas

– Describe the operating characteristics of

natural gas fueled vehicles

– Identify the unique characteristics of

fuel-ignition and combustion of natural gas

CONTENTS OBJECTIVES

Compressed Natural Gas VehiclesWhat Is Natural Gas?

Alternative Fuel Comparison TableIdentification of Ford Dedicated and Bi-Fuel CNG Vehicles

Changes to Base Vehicle Components

on Dedicated and Multiport Bi-FuelCNG Vehicles

Changes to Base Vehicle OperatingStrategies

Supplemental Information On AlternativeFuel Vehicles

LESSON 1: INTRODUCTION TO CNG VEHICLES

Ford Clean-Earth Logo

Ford Motor Company is a leader in the development and introduction of alternative fueled vehicles Formore 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/ & 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 allcarbon monoxide (CO) pollution They also are the second largest national source of hydrocarbons (HCs) at 29percent and nitrogen oxides (NOx) at 31 percent, the major ingredients of unhealthful ground-level ozone Inmany urban areas, motor vehicles are the single largest source of major criteria pollutants Motor vehicles alsoemit 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 willcontinue to grow

Due to the favorable properties of natural gas as an engine fuel, Compressed Natural Gas (CNG) fueledvehicles produce lower levels of all pollutant emissions than either conventional or reformulated gasolineand 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 gas

as 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

LESSON 1: INTRODUCTION TO CNG VEHICLES

Alternative Fuel Comparison Table

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

c i t

1 1 2 c b i c f e t =

e il o s a f o o ll a 1

8

l e f

s n

r e r a l

s e m it 5 3 s i k n T

r e r a l

s e m it 8 1 s i k n T

r e r a l

5 1 s i k n T

r e r a l s e m it

e r u

° 0 1 , 1 - 0 9

% 0 - 2

/ F

° 0 2 , 1

% 5 - 5

/ F

° 0 8

% 6 - 7

/ F

° 0 8

% 9 - 3

/ F

° 0 9 - 0 4

% 8

r e

r e w

d r a n t S

n I s a l a r u t a o t y l n

y t u t h il a , s t s e t A E

e l c i h v e a o r p

s e l

% 3 d tt m e

, e i x o o m n b r a c

n g r ti n s e l

% 7

s e l

% 3 d a e i x o

e r e t ( s n b r a c o r d y h

r o l o o c l a o e r e w

e v it a r o a v e

n h t ) s n i s i m e e il o s a

t s e a l c ll a r e v O

n I e f s o f g i n r u

y t u t h il a , s t s e t A E

e l c i h v s a l a r u t a

s e l

% 8 d tt m e

% 5 , e i x o o m n b r a c

d a e i x o n g r ti n s e l

e a t e m - n n s e l

% 5

e r e t ( s n b r a c o r d y h

r o l o o c l a o e r e w

) s n i s i m e e v it a r o a v e

e il o s a n h t

t h il a , s t s e t A E n I

e l c i h v l o a t e m y t u

s e l

% 5 8 d tt m e

, e i x o o m n b r a c

n g r ti n s e l

% 2

s e l

% 5 8 d a e i x o

s e s a c i n g r o e v it c a r

e a t e m - n n (

l o o c l a , s n b r a c o r d y h

n h t ) s e y h d l a d a e il o s a

s e l

% 0 - 5 n b r a c

c n I.

-e i x o o m

n g r ti n d s a

e v it a l e r e i x o

e il o s a o t

t s n i a a d r a n t S

e r a s r e t o c i h w

d r u s a m

g i n if e r

/ s a l a r u t a N

li o e u r C

/ s a l a r u t a N l a C

d a r a u S

/ s p r c h c r a t s

s a m o i B

li o e u r C

Identification of Ford Dedicated and Bi-Fuel CNG Vehicles

1FTEF2595VLA00001

Eighth 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 madeusing 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 criticalareas of the CNG and driver control systems

LESSON 1: INTRODUCTION TO CNG VEHICLES

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

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 This

is 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 Victoria

2004 1/4 Dedicated CNG E-Series

YesYesYesYesN/AN/AYesYesYesNoYes

CNG/GasolineSCP90-Pin

No

No

NoN/A

Yes

YesYesYes

YesYes

YesYes

N/AYesYes

YesYesYes

YesYesYes

YesYesNo

N/AYesN/A

YesYesN/A

YesNoYes

CNGSCP90-Pin

Yes = Enabled

No = Not Enabled

N/A = Not Applicable

LESSON 1: INTRODUCTION TO CNG VEHICLES

Supplemental Information On Alternative Fuel Vehicles

There are many places where supplemental information can be obtained on AFVs The following list providesvarious organizations, phone numbers, and websites where information is available for AFVs

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LESSON 2A: DEDICATED CNG OPERATION

Upon completion of this lesson the student will

be able to:

– Identify the characteristics of natural gas

– Describe the operating characteristics of

natural gas fueled vehicles

– Identify the unique characteristics of fuel

ignition and combustion of natural gas

– Explain the theory and operation of

dedicated CNG fueled vehicles

CONTENTS OBJECTIVES

Dedicated CNG Vehicle Theory Of OperationCNG Fuel System Pressures

LESSON 2A: DEDICATED CNG VEHICLE OPERATION

DEDICATED CNG VEHICLE THEORY OF OPERATION

Typical Dedicated CNG Vehicle Components

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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 CNGfuel

LESSON 2A: DEDICATED CNG VEHICLE OPERATION

Typical Dedicated CNG Component Configuration (Crown Victoria Shown)

DEDICATED CNG FUEL SYSTEM THEORY AND OPERATION (continued)

4 16

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 & Series) and distributes it to the fuel rails via low-pressure fuel lines, through an open low-pressure solenoidshut-off valve

F-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

LESSON 2A: DEDICATED CNG VEHICLE OPERATION

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CNG FUEL SYSTEM PRESSURES

CNG fuel systems operate at very high pressures However, these pressures will change as the fuel passes alongthe fuel delivery system The following is a description of the fuel pressures and how they change at differentpoints 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

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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 psi

on 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)

LESSON 2A: DEDICATED CNG VEHICLE OPERATION

NOTES

CONTENTS OBJECTIVES

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

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 — 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 andanswer 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

D I

V A T F E

I L F V P R F V S F F V S F M V S F

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1 N S P M T

2 N S P M T

ACTIVITY 2A

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

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

_ _ _

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 internal

combustion engine? _ _

PAGE#

7 Write the meaning of the acronyms listed below

M Y N O R C

M C F A

P T F T T F T F E P R F

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

STUDENT ANSWER SHEETDirections: 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 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 NOT

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

ACTIVITY 2A

NOTES