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2009-2011 Ford E-150 / E-250 / E-350

1. 1 77 Installing Fuel Fill Line Fuel Filter to Tank 1 77 Installing Fuel Lines Tank to Engine 1 U U u enne nnne nnn tran nnn nnn 78 Installing Fuel Rail Pressure Control Module U u u J J 80 Installing Pressure Relief Hose U U U u u u uuu u J 81 SPECIFICATIONS D as anena 83 Engine SpecificationS uuu 83 ROUSH CleanTech Conversion Ford 5 4L LPI Engine J J 83 Chassis Sp cCificationsS ii ks ka kk aa kk ko a a 83 Fastener Torque Value creatio a ki n orta kk n n n a n n n n A kk Eu 84 SERIES RER ak kb kb e a ke kk wa a 85 Fuel System Flow DUSSIER ENEE 85 l an 85 Electrical Wiring DIagFamis uiuos uu au kk ENEE ERAN A kk kk kk 86 Wiring Harness Electrical Diagram U U u u uu u 86 In Tank Wire Hammess C U U u u uu u u u J 87 TOOLS AND EQUIPMENT uu uu uuu uuu x dx ea oru Sd amer Eege 88 Special TOOIS Ec 88
2. y a D d Figure 74 Fuel Filter Assembly Typical 5 If no additional assembly is required open the manual shutoff valve and replace the Multivalve cover 90 degree elbow and pressure relief hose if applicable 6 Connect the battery 2 11 2011 75 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Installing Fuel Filler Neck A Caution Hand tighten all fuel line connectors and fasteners before applying a wrench to avoid cross threading Failure to heed this caution can result in component damage 1 Attach the fill valve to the fuel filler neck mounting bracket Install the nut and tighten to the specified torque NG J Figure 75 Fill Valve and Fuel Filler Neck Mounting Bracket 2 Install the fill valve and fuel filler neck and mounting bracket to the vehicle side panel behind the vehicle fuel fill door Install and tighten the bolts to the specified torque Figure 76 Fuel Filler and Door 3 Install the fuel fill line to the fill valve and fuel filler neck 4 If no additional assembly is required open the manual shutoff valve and replace the Multivalve cover 90 degree elbow and pressure relief hose if applicable 5 Connect the battery 2 11 2011 76 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Installing Fuel Fill Line Filler Neck to Filter 1 Connect the fuel
3. 33 Fel Fa On tete a en e a ak at n n ati n EE 36 MAINTENANCE REQUIREMENTS U J 37 Schedul u uu 37 MAINTENANCE PROCEDURES u J J 37 Intake Air Filter Inspection H 37 In Line Fuel Filter Replacemen t U u J J 38 REPAIR PROCEDURE Goa ua r k n dw me kq kw kt w ek nao nex Fa Cra s ana e kde ka n Us A era pe PEE DA RE DADE kinan 39 Preparing Vehicle for Service U u 39 AlerttMeSsag S EENS 39 Changing E 40 Pressure Reliefezu usa a a ki au b oi ki us T 41 P rging E 41 Purging the Fuel Tank U U gn u uu uu u u u 41 Purging System Fuel Lines U u uu uu uu u uuu nass J 41 Manual Fuel Shutofl 55 eee kn n n a ak n SS n Sas 42 Opening Manual Shutoff Valve U U u nnns sauna inn u tnn sanas 43 Fuel System Component Removal Procedures eese 44 Removing Pressure Relief Hose lueeeeeeeeeeeeeiieeeeeeeees esee nene nnnm nhan unns enn nnt inna sanas ssa nant R nana nns 44 Remo
4. Figure 63 Fuel Fill Line at Filter Outlet 2 11 2011 68 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 26 Turn the manual shutoff valve counterclockwise until it stops This opens the fuel supply to the system Note The manual shutoff valve can be hard to turn From fully open to fully closed is approximately 2 1 2 turns Figure 64 Multivalve Assembly 1 Electrical Pass 5 Fuel Filler Inlet Through not Elbow serviceable 6 Fuel Return Line 2 Manual Shutoff 7 Pressure Relief Valve Valve 3 Fuel Supply Solenoid 4 Fuel Supply Line 27 Install the Multivalve cover and attach the 90 degree elbow to the pressure relief valve on the cover Make sure the elbow is tight and leads to the driver s side of the vehicle oriented toward the pressure relief hose A Caution Hand tighten the 90 degree elbow to avoid cross threading Failure to heed this caution can result in component damage Note When installing the 90 degree elbow and brass tube to the Multivalve use anti seize on the threads prior to assembly 2 11 2011 69 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 28 If applicable install the pressure relief hose to the 90 degreee elbow and attach the spring clamp Figure 65 Spring Clamp and Pressure Relief Hose 29 Install the negative battery cable 30 Refer to th
5. e E Series under hood at front passenger side Figure 3 VECI Label Location 2 11 2011 5 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement DESCRIPTION AND OPERATION System Overview The ROUSH CleanTech Liquid Propane Autogas LPA system consists of a propane fuel tank fuel pump fuel rails and lines injectors and electronic controls The system is simple and easily serviced with no user adjustment required FUEL RAIL amp INJECTORS FUEL TANK Figure 4 LPI Fuel System Typical Propane is stored in the vehicle fuel tank under pressure as a liquid The pressure in the tank is determined by the temperature of the fuel ranging from 0 psi at minus 44 F to 312 psi at 145 F The tank has an overpressure safety device which vents the tank at pressures over 312 psi There are three propane filters in the system The primary filter is located in the fuel fill line which is intended to filter out the majority of contaminants that may be present in the fuel The primary filter must be replaced every 50 000 miles A secondary fuel filter is located after the fuel pump inside the tank which is intended to ensure that no contaminants reach the fuel injectors The third filter is a sock filter located at the bottom of the fuel pump fuel pump inlet ROUSH CleanTech LPA vehicles require HD 5 propane rated for automotive use Us
6. 2 11 2011 iv ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement INTRODUCTION General Information This manual applies to the following ROUSH CleanTech Liquid Propane Autogas applications e 2009 2011 E 150 E 250 E 350 5 4L 2V This manual is a supplement to the regular Ford Workshop Manual covering the unique components of the ROUSH CleanTech Liquid Propane Autogas system e Fuel supply line e Fuel return line e Fuel Rail Pressure Control Module FRPCM e Fuel rails e Fuel filler lines valve and filter e Fuel tank The ROUSH CleanTech parts generally serve the same functions as the Ford parts they replace The online Ford Workshop Manual if available continues to apply to all other details The diagnostic chart in this manual directs the technician to appropriate sections of the Ford manual for applicable remedies in some situations Propane like other fuels must be handled safely with knowledge of its characteristics Training in propane characteristics and handling is available through the Propane Education and Research Council PERC 1140 Connecticut Avenue Washington DC 20036 Their web address is www propanecouncil org ROUSH CleanTech Technical Assistance Call ROUSH CleanTech Customer Service at 1 800 59 ROUSH with any questions regarding ROUSH CleanTech Liquid Propane Autogas systems Start Sequence The ROUSH CleanTech Liquid Propane Autogas system is fully integ
7. 2 Connect the forward fuel return line to the lower left port of the FRPCM and tighten the fitting to the specified torque eee yi 2 l A VP lt S ge eh d ab Ay 3 T Y KC 1 A wl 2 L SL Z Connect the Fuel ts j Return Line to the N a i 7 i mm A A gt zl l nd Figure 79 Forward Fuel Return Line at FRPCM 2 11 2011 78 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 3 Connect the forward fuel supply line to the upper right port of the FRPCM and tighten the fitting to the specified torque Figure 80 Forward Fuel Supply Line at FRPCM 4 Attach the forward fuel lines to the retention clips on the frame rail exhaust heat shield and to the retention bracket on the bell housing Make sure all sleeves are positioned correctly between retention clips and bell housing bracket Bend the crimp tabs to retain the fuel lines and VMV line 5 Connect the tank fuel supply line to the forward or intermediate fuel supply line and tighten the fitting to the specified torque 6 Connect the tank fuel return line to the forward or intermediate fuel return line and tighten the fitting to the specified torque Figure 81 Fuel Supply and Return Lines 2 11 2011 79 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 7 Open the manual shutoff valve on the fuel tank 8 C
8. 2 11 2011 55 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Note The manual shutoff valve can be hard to turn From fully open to fully closed is approximately 2 1 2 turns Figure 41 Multivalve Assembly 1 Electrical Pass 5 Fuel Filler Inlet Through not Elbow serviceable 6 Fuel Return Line 2 Manual Shutoff 7 Pressure Relief Valve Valve 3 Fuel Supply Solenoid 4 Fuel Supply Line 2 11 2011 56 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 6 Disconnect the fuel tank to filter fuel fill line at the outlet of the fuel filter Figure 42 Fuel Fill Line at Filter Outlet 7 Disconnect the fuel tank fuel supply line and fuel return line from the forward or intermediate fuel supply line and the forward or intermediate fuel return line Figure 43 Fuel Tank Fuel Supply and Fuel Return Line Connections 8 Detach the fuel lines from the double snail retaining clip on fuel line support bracket when applicable just to the rear of the fuel line connections 9 Obtain a hoist capable of safely lifting 1000 pounds Attach the hoist to the fuel tank using lifting straps Support the tank while removing the tank mounting fasteners 2 11 2011 57 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 10 Remove the nuts bolts and steel washe
9. E d r JA me YA ke kas t 5 k d pi Figure 71 Left Side Fuel Rail 4 Connect the fuel return line at the rear end of the left side fuel rail 5 Connect the crossover fuel line to the left side fuel rail and tighten to the specified torque zs we uu d A A fud Em gt Le la YE i a Cen A Y 1 Ka yo f m j Figure 72 Crossover Fuel Line 6 Connect the fuel injector electrical connectors 7 Connect the Injection Pressure and Temperature Sensor IPTS electrical connector Figure 73 Fuel Rail with Injection Pressure and Temperature Sensor 8 Connect the heated PCV hose to the intake manifold 2 11 2011 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 9 Attach the throttle body inlet hose 10 Connect the Mass Air Flow sensor electrical connector 11 If no additional assembly is required open the manual shutoff valve and replace the Multivalve cover 90 degree elbow and pressure relief hose if applicable 12 Connect the battery Installing Fuel Filter Assembly 1 Assemble the filter assembly in the screw clamp 2 Tighten the clamp screw to the specified torque 3 Connect the line from the filler neck to the inlet end of the fuel filter and tighten to the specified torque 4 Connect the line from the tank to the outlet end of the fuel filter and tighten to the specified torque A Fa SN Ba
10. gallon of propane and cycle the ignition key to the crank position and then to the off position Do not allow the vehicle to start during this step Inspect and monitor for any leaks Remove the bleeder valve cap and open the bleeder valve for 10 minutes or until propane stops bleeding whichever comes first Close the bleeder valve and install the bleeder valve cap Fill the tank with five gallons of propane Note The next step confirms if any leaks are present in the fuel system 6 Perform a final leak inspection at all fuel fill and fuel line connections to ensure no leaks are present using Snoop or a dish soap and water mixture Perform End Of Line EOL testing and road test Verify that there are no concerns and fill the vehicle and record the total amount of gallons to fill the vehicle Installing Under Vehicle Tank A Caution Hand tighten all fuel line connections and fasteners before using a wrench to avoid cross threading Failure to heed this caution can result in component damage 1 2 Insert the tank end of the fuel supply line 2 and the fuel return line 1 through the tank collar grommet 3 Install the tank collar grommet onto the tank collar 2 11 2011 61 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 3 Carefully install the wiring harness through the upper right hole of the tank collar grommet Figure 50 Fuel
11. Autogas 2011 Service Manual Supplement REPAIR PROCEDURES Preparing Vehicle for Service Alert Messages The following alert messages appear from time to time in appropriate places in this manual Ensure that all personnel in the immediate area are aware of these reminders A Danger Propane is nontoxic nonpoisonous has the lowest flammability range of any alternative fuel and dissipates quickly when released into the atmosphere Propane vapor is heavier than air and seeks the lowest point When the ratio of propane to air is between 2 296 and 9 6 propane burns in the presence of an ignition source at 940 F 504 C or hotter Keep away from heat sparks flames static electricity or other sources of ignition Failure to heed this danger can result in severe personal injury A Danger Fuel supply lines remain pressurized after engine shutdown Keep away from heat sparks flames static electricity or other sources of ignition Do NOT enter storage areas or confined spaces unless they are adequately ventilated Failure to heed this danger can result in severe personal injury A Danger Propane is heavier than air and seeks the lowest available level when released to the atmosphere Keep heat sparks flames static electricity or other sources of ignition out of the area when venting or purging the fuel lines or tank Failure to heed this danger can result in severe personal injury or property damage A Warning Liquid propane
12. Lines and Tank Collar Grommet 4 Install the fuel fill line through the lower center hole in the tank collar grommet 5 Assemble the fuel fill line to the 90 degree fitting on the Multivalve Support the fitting while tightening the fill line to the specified torque Li Figure 51 Fuel Fill Line 6 Position the fuel supply solenoid and install the E clip 2 11 2011 62 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 7 Connect the fuel supply line and the fuel return line to the Multivalve quick connect supply and return ports Give each line a firm pull to make sure that the quick connect fittings have locked into position Fuel Fill Line P10C2 9047 AA Wiring harness located here removed for clarity Install 350 PSI Design Pressure Label here Y Ee Ze bn Fuel Return Line St E Be Fuel Supply Line li l AY Figure 52 Multivalve Connections 8 Connect the fuel supply and fuel return lines to the retention clip on the tank strap bracket Fuel Return Line Fuel Supply Line P Figure 53 Fuel Lines and Retention Clip Typical 9 Install the convolute tubing onto the fuel fill line and the electrical cables 2 11 2011 63 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 10 Install the convolute tubing over the fuel supply and return lines Figure 54 Fuel Lines Wiring
13. Solenoid The valve also incorporates double back redundant check valves that close when vehicle fuel tank pressure is greater than the pressure outside of the tank to prevent fuel from escaping The valve is part of the Multivalve Fuel Control Solenoid Closed when the engine is running but still allows fuel to flow through a metered orifice back to the vehicle fuel tank The solenoid is opened for approximately 15 seconds after the engine is turned off to allow pressure in the fuel rails to return to the vehicle fuel tank The solenoid may also be opened to flush the fuel rails to ensure that there is liquid fuel in the fuel rails during hot operating conditions On E Series vehicles the solenoid is part of the FRPCM Fuel Fill Filter In line between the Fill Valve and the fuel tank to filter fuel before entering the vehicle fuel tank during the fill process Fuel Fill Solenoid Electrically operated solenoid used to allow fuel to enter the vehicle fuel tank during fills The solenoid is located inside of the vehicle fuel tank and is attached to the Multivalve Fuel Level Sending Unit Located inside of the vehicle fuel tank to indicate fuel level The unit consists of a float on an arm with a wound resistor Fuel Rail Pressure Control Module FRPCM Module consisting of four normally closed solenoids controlled by a separate electronic control module The FRPCM is mounted on the engine The module is used only in E Series ve
14. aligned and fully seated on the frame and cross members install the four crush limiters and tank mounting isolators Figure 59 Lower Isolator and Crush Limiter 2 11 2011 66 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 20 Loosely install the steel washers and outboard tank mounting bolts into the frame mounts Do not tighten until all tank mounting fasteners are aligned and installed Figure 60 Outboard Fuel Tank Mounting Bolt and Washer 21 Loosely install the two steel washers and nuts onto the front and rear crossmember bracket studs Figure 61 Inboard Fuel Tank Mounting Nut and Washer at Crossmember 22 With all fuel tank mounting fasteners installed tighten the two nuts and two bolts to the specified torque 2 11 2011 67 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 23 Connect the fuel supply line and fuel return line to the forward or intermediate fuel supply line and the forward or intermediate fuel return line Tighten the fuel line fittings to the specified torque Figure 62 Fuel Line Connections at Forward Fuel Lines 24 Attach the fuel lines to the double snail retaining clip on fuel line support bracket just to the rear of the fuel line connections 25 Connect the fuel tank to filter fuel fill line to the outlet of the fuel filter Tighten the fitting to the specified torque
15. is cold The temperature of propane in its liquid state is 44 F 42 C Wear eye and ear protection during venting and repair operations Keep moisture away from the valves Failure to heed this warning can result in personal injury Note Identify the condition good stuck open stuck closed or inoperable of each solenoid valve prior to venting the fuel tank to ensure that the solenoid valves are not the reason for vehicle service and unnecessarily venting the tank 1 Gasoline auto ignition occurs at a much lower temperature 430 500 F 221 260 C 2 11 2011 39 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Changing Fuses Figure 20 Fuse Panel The fuse panel is located on the bulkhead under the hood on the driver s side Figure 21 20 Amp and 15 Amp Fuses Always use a fuse of the correct amperage when replacing fuses 2 11 2011 40 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Pressure Relief There are two means of relieving excess pressure in the tank the pressure relief valve in the Multivalve and the bleeder valve in the tank wall or remote bleeder valve on frame rail that is separate from the Multivalve The pressure relief valve in the Multivalve vents excess pressure to the atmosphere through a hose that directs the release to a point at the bottom of a rear wheel opening The pres
16. switch to close In order for the switch to close pressure in the fill line must be at least 10 psi higher than tank pressure otherwise no fill is possible 3 The fill pressure switch provides a ground to the 80 level sensor to activate the circuit If the fuel level is below the 80 level the sensor provides ground to the fuel fill solenoid allowing fuel to enter the tank 4 Once the fuel reaches the 80 fill level the 8096 level sensor de activates causing the fill solenoid to close Note Some fuel pumps may have sufficient pressure to allow a small fuel flow into the tank even with the fill solenoid closed The operator should stop the fill as soon the fuel flow drops noticeably Vehicle Starting The ROUSH CleanTech LPA system is fully integrated using Ford s One Touch Integrated Start OTIS system When the ignition key is turned to crank and released to the ON position the PCM opens the Flow Control Solenoid FCS and engages the fuel pump As soon as the fuel rail temperature and pressure are acceptable to ensure liquid fuel at the injectors the starter engages and the vehicle starts with no further action required from the operator This delay period is usually less than 5 seconds but may be up to 30 seconds in extremely hot conditions During the delay period the wrench light on the dash blinks to signal that the system is active 2 11 2011 7 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service M
17. tabs 8 Connect the VMV 90 degree fitting to the FRPCM vacuum port 9 Connect the FRPCM electrical connector Installing Pressure Relief Hose 1 Connect the pressure relief hose to the 90 degree elbow in the Multivalve cover Retain with spring clamp 2 11 2011 81 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 2 If applicable connect the pressure relief hose to the outlet nozzle bracket at the inner rear fender support Constant tension clamp here Figure 87 Pressure Relief Hose Lower Connection 2 11 2011 82 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas SPECIFICATIONS 2011 Service Manual Supplement Engine Specifications ROUSH CleanTech Conversion Ford 5 4L LPI Engine Bore and Stroke 90 2 mm x 105 7 mm Compression Ratio 9 0 1 Displacement 5 4 Liters Engine Architecture V8 SOHC Fuel System Port Fuel Injection Liquid Propane Injection Peak Power Rating 255 HP Peak Torque Rating 350 Ib ft Transmission 4 Speed Automatic with Overdrive Valve Operation Variable Cam Timing Valve Count 2 per cylinder Valve Sizes 31 6 mm 27 65 mm Need Valve Sizes Equipment Air Conditioning Standard Heavy Duty Payload Package Optional Tires and Wheels Variable with option package Trailer Tow Package Required Chassis Specifications Regular Extended M
18. to crank or run Compare fuel rail pressure with fuel tank pressure Fuel rail pressure should be at least 50 psi higher than fuel tank pressure FUEL RAIL PRESSURE FUEL RAIL PRESSURE FUEL RAIL PRESSURE 50 PSI OR MORE NEAR EQUAL TO OR 25 40 PSI MORE THAN FUEL TANK LESS THAN FUEL THAN FUEL TANK PRESSURE TANK PRESSURE PRESSURE Fuel Pump OK Does fuel pump run Carefully disconnect pressure gauge from fuel rail making sure to NO NOT relieve pressure in CERTAIN Go to Step 9 gauge hose very slowly Go to Step 5 With engine running disconnect Flow Control Solenoid FCS and check fuel pressure PRESSURE GOES PRESSURE GOES PRESSURE UNCHANGED HIGHER LOWER FCS energized I FCS stuck open replace should not be FCS working properly FCS and retest Check for short in supply circuit to FCS repair and retest 2 11 2011 28 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 5 CHECK MULTIVALVE SOLENOID ACTUATION Wiring Pass Through Overpressure Relief Manual Shutoff Fuel Return Fuel Supply to Engine Figure 13 Multivalve Procedure Turn ignition switch to off position if not already done Disconnect 6 pin fuel tank harness connector located on wire loom at fuel tank from vehicle harness Connect positive lead of voltmeter to the Pink Black wire Pin xx and negative lead to the Brown White wire Pin xx on vehicle side of harness connector Turn ig
19. 0 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Removing Fuel Rail Pressure Control Module 1 Purge the propane from the fuel lines E E T dE E Remove the rear throttle body spacer fastener and install the FRPCM Re em St install this fastener once the M6 x 62 bolts attach module TF f FRPCM is in position to the intake manifold Figure 25 Fuel Rail Pressure Control Module FRPCM 2 Close the manual shutoff valve on the tank 3 Disconnect the FRPCM electrical connector 4 Bend open the crimp tabs on the retention bracket 5 Disconnect the forward fuel supply line from the upper right port of the FRPCM 6 Disconnect the jumper fuel line from the RH fuel rail and from the lower right port of the FRPCM 7 Disconnect the jumper fuel line from the LH fuel rail and from the upper left port of the FRPCM 8 Disconnect the forward fuel return line from the lower left port of the FRPCM 9 Disconnect the VMV 90 degree fitting from the FRPCM vacuum port 10 Remove the bolts securing the FRPCM Remove the FRPCM Removing Fuel Lines Tank to Engine Note The fuel supply and fuel return lines quick connected into the fuel tank Multivalve are serviceable only with the fuel tank removed 1 Purge the propane from the fuel lines 2 Close the manual shutoff valve on the tank 3 Disconnect the tank fuel supply line from the forward or intermediate fuel supply line 2 11 2011 45
20. BOVE TANK PRESSURE Go to Step 2 Has the vehicle been exposed to high ambient air temperatures and or driven for an extended period Allow vehicle fuel tank to cool possibly Go to Step 3 Excess tank overnight and then attempt to refill pressure or malfunctioning Note If the vehicle tank is hot the pressure in fill station tank may increase to the point that fill station pressure may not be sufficient to fill the tank or fill slower than usual 2 11 2011 24 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 3 CHECK FOR RESTRICTIONS IN THE FUEL FILL SYSTEM Procedure 1 Check for kinks or restriction in the tank blue fill hose 2 Verify that the fuel filter is not plugged 3 Verify that the Fill Valve is functioning properly NO RESTRICTIONS OR PLUGGED FILTER Go to Step 3 RESTRICTIONS AND OR PLUGGED FILTER Repair as required and retest 4 CHECK CURRENT FLOW TO THE TANK FILL CIRCUIT Refer to wire harness drawing in Section 9 SCHEMATICS specific to the vehicle you are diagnosing Locate the 5 amp E Series or 15 amp F Series fuse for the fill circuit Procedure 1 Remove 5 amp or 15 amp fuse from mini fuse holder in half fuse box under hood driver s side 2 Connect an ammeter across terminals in fuse holder 3 Attempt to fill tank while watching ammeter Note Ammeter should read 0 7 0 95 amps if fuel fill circuit is activated If ammeter reads n
21. ERY VOLTAGE CORRECT Repair open circuit in ROUSH Refer to the Ford Workshop CleanTech harness from 4 pin Manual to determine fault connector to 6 pin connector 2 11 2011 35 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 4 CHECK RESISTANCE ACROSS TERMINALS OF FUEL SENDING UNIT Figure 17 Fuel Sending Unit 6 Pin Connector Terminals Procedure 1 Place positive probe of ohmmeter on Yellow wire Pin E and negative probe on Black Orange wire Pin F 2 Measure resistance across the terminals and check resistance reading against the Fuel Fill Table below for fuel level in vehicle being tested Note The measured resistance should indicate the amount of fuel in the tank Fuel Fill Table Resistance ohms Model Tank Configuration Full 3 4 1 2 1 4 Empty E 150 E 250 E 350 Under Vehicle 15 30 55 90 160 2 11 2011 36 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement MAINTENANCE REQUIREMENTS Schedule With the exception of the fuel system follow the Ford Maintenance Schedules and Workshop Manual for all E Series and F Series maintenance requirements For the ROUSH CleanTech LPI fuel system refer to the schedule and procedures below Operation Maintenance Interval In line Fuel Filter Replacement 50 000 miles 80 000 km MAINTENANCE PROCEDURES Intake Air Filte
22. RH RAIL INLET D RH RAIL OUTLET TO CROSSOVER E LH RAIL INLET FROM CROSSOVER F LH RAIL OUTLET TO FRPCM G FRPCM INLET FROM LH RAIL H FRPCM OUTLET TO FUEL TANK FUEL RAIL PRESSURE CONTROL MODULE BLEED OUTLET TO VMV CANISTER FUEL SUPPLY LINE FUEL RETURN LINE Figure 11 Fuel Rails and Injectors Early Applications 2 11 2011 15 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Chassis Fuel Lines and Tank FUEL RAIL amp INJECTORS FUEL TANK Figure 12 Fuel Lines and Tank Typical 2 11 2011 16 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement TROUBLESHOOTING Symptom Tables Fuel Odor Content to be developed 2 11 2011 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Diagnostic Flow Charts No Fill Condition 1 VERIFY VEHICLE BATTERY IS FULLY CHARGED AND CONNECTED Go to Step 2 Check battery connections and charge repair as required Attempt to fill vehicle fuel tank again 2 VERIFY THAT VEHICLE FUEL TANK IS ACTUALLY LOW ON FUEL AND NOT ALREADY FULL Preliminary check 1 Check fuel gauge in instrument cluster or refer to Fuel Sending Unit Diagnostics for measuring resistance of fuel sending unit Note If fuel level is at 8096 of tank capacity full fill sole
23. ROUSH CLEANTECH 2009 2011 Ford E 150 E 250 E 350 LIQUID PROPANE AUTOGAS Rev 02 11 2011 SERVICE MANUAL SUPPLEMENT ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement FOREWORD This manual is a supplement to the Ford E 150 250 350 Workshop Manuals referenced as the Ford WSM where applicable in this manual It is intended to provide technicians with the procedures required to maintain and service the unique components of the ROUSH CleanTech E 150 250 350 Liquid Propane Autogas vehicles Service procedures for vehicle components shared in common with Ford E 150 250 350 vehicles will be referenced to and covered in the Ford Workshop Manual This manual supplement includes a Table of Contents to direct you to the information contained within LIMITED LIABILITY DISCLAIMER The information in this publication was accurate and effective at the time the publication was approved for printing and is subject to change without notice or liability ROUSH CleanTech reserves the right to revise the information herein and to make changes and discontinue production of described parts at any time 2 11 2011 i ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement TABLE OF CONTENTS PORE W ORD eo W kk EE e L l LIMITED LIABILITY DUSEL ANER eege l TABLE OF CONTENTS
24. ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 4 Disconnect the tank fuel return line from the forward or intermediate fuel return line WK Figure 26 Fuel Supply and Return Lines 5 Disengage the fuel lines from the retention clips on the frame rail exhaust heat shield and bell housing fuel line retainer 6 Disconnect the forward fuel supply line from the upper right port of the FRPCM Figure 27 Forward Fuel Supply Line at FRPCM 2 11 2011 46 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 7 Disconnect the forward fuel return line from the lower left port of the FRPCM 2 FS P Figure 28 Forward Fuel Return Line at FRPCM 8 Remove the forward fuel lines from the retention clips on the frame rail heat shield and from the retention bracket on the bell housing Removing Fuel Fill Line Filter to Tank Note The fuel fill line cannot be disconnected from the Multivalve before the tank is removed from the vehicle A Danger A trace amount of propane fuel will be released when loosening the fittings Propane settles to the lowest available surface before dissipating into the atmosphere Keep heat sparks flames static electricity or other sources of ignition out of the area when venting or purging the fuel lines or tank Failure to heed this danger can result in sever
25. SI Design Pressure Label here Fuel Return Une Return Line T Mes Fuel FuelSupplyLine Line Li Figure 47 Multivalve Connections 2 11 2011 59 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 18 Disconnect the fuel supply and fuel return lines from the retention clip on the tank strap bracket Fuel Return Line EN E Fuel Supply Line Figure 48 Fuel Lines and Retention Clip Typical 19 Pull the fuel lines out of the tank collar grommet 20 Remove the E clip and pull off the fuel supply solenoid 21 Remove the fuel fill line from the 90 degree fitting on the Multivalve A Figure 49 Fuel Fill Line 22 Pull the fuel fill line through the tank collar grommet 23 Remove the fuel tank collar grommet and carefully slide it off of the wiring harness 2 11 2011 60 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Fuel Tank Installation Procedures LPA System Bleed and Fill Procedure The following procedure is required in order to ensure that the fuel system is leak free and that any residual nitrogen is removed from the system Failure to complete this process could result in leaks excessive tank pressure and filling problems 1 5 Bleed tank from the bleeder valve to ensure no air is present in the system Close the bleeder valve Fill the tank with 0 1 1 10
26. all the pressure to bleed from the fuel rail When pressure is fully bled off the solenoid closes preventing fuel from entering the EVAP system Injection Pressure and Temperature Sensor IPTS The IPTS is used to monitor fuel pressure and temperature On E Series applications the IPTS is read by the SRM and communicated to the PCM over CAN Figure 6 Injection Pressure and Temperature Sensor 2 11 2011 9 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Fuel Supply and Return Lines The Ford OEM fuel lines are replaced with formed stainless steel lines following the original production line routings The formed lines are produced in many lengths and configurations to accommodate the various vehicle models The lines may be installed with two or three sectioned assemblies depending on the specific vehicle model All sections supply and return include unions as part of the assembly The stainless steel fuel lines are retained in the chassis using the Ford OEM retention clips _DSC5217 NEF i _DSC5216 NEF Figure 7 Stainless Fuel Supply and Return Lines Typical Fuel Tank Different tank configurations are used based on the vehicle model A long cylindrical tank mounted under the vehicle is used for the E 150 250 350 LPA vehicles The tank is bolted to Figure 8 Fuel Tank Under Vehicle Configuration 2 11 2011 10 ROUSH CleanTe
27. and Convolute Tubing 11 Arrange the fuel lines and wiring harness as shown so that the Multivalve cover can be easily installed Figure 55 Fuel Line and Wiring Arrangement 2 11 2011 64 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 12 If removed secure one rubber isolator to the top side of each of the tank mounting brackets Use a high strength fast curing adhesive to keep the isolators in place Figure 56 Upper Isolator 13 Attach the hoist and the lifting straps to the fuel tank 14 Position the fuel tank under the vehicle 15 Tuck the fuel lines fuel fill line and wiring harness up against the fuel tank Slowly raise the tank to approximately 12 18 inches from its installed position 16 Connect the fuel tank 6 pin connector to the main body harness connector Install tie straps as necessary to secure the harness 2 11 2011 65 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 17 Route the fuel fill line toward the outlet of the fuel filter Connect the line to the filter after the fuel tank is fully installed Route the Fuel Fill hose over tank as shown prior to raising the tank into its final position Figure 58 Position Fuel Fill Line 18 Raise the fuel tank into position Make sure to align the mounting holes of the tank with the four mounting bracket holes 19 With the tank brackets
28. anual Supplement System Components and Function Fuel Rails and Injectors The Ford OEM fuel rails and injectors are replaced with ROUSH CleanTech LPA fuel rail and injector assemblies including injection pressure and temperature sensor IPTS Schrader port for service and crossover fuel line On E Series vehicles only the LPA system also incorporates a Fuel Rail Pressure Control Module FRPCM mounted at the top rear of the engine FRPCM SOLENOID LEGEND FUEL RAIL PRESSURE Q s y CONTROL MODULE f FRPCM LE db Q RETURN hi SN FLow contRoL AC Gg Wel ge SIAN SY M NYS LI ki NN S N FIE SS U gt ai Ta BLEED OUTLET ND TO VMV L E 7 CANSTER Ne V SYSTEM FLOW PATH Ki l A FRPCM INLET FROM FUEL TANK WKY B FUEL OUTLET TO RH RAIL n EN C RH RAIL INLET D RH RAIL OUTLET TO CROSSOVER l l wi I S F LH RAIL OUTLET TO FRPCM FUEL RETURN LINE r G FRPCM INLET FROM LH RAIL H FRPCM OUTLET TO FUEL TANK LLI E LH RAIL INLET FROM CROSSOVER Figure 5 Fuel Rails and Injectors with FRPCM Early Applications The FRPCM is a unit consisting of four normally closed solenoids controlled by a separate electronic control module The FRPCM is controlled directly by the Smart Relay Module SRM which is in turn controlled by the PCM Included in the FRPCM are Supply Solenoid Open energized when the engine is running the supply solenoid allows fuel to
29. ata ROUSH CleanTech emissions certification information is recorded on the ROUSH CleanTech Vehicle Emissions Control Information VECI label The label is vehicle specific and is required by law to be on the vehicle to which it is assigned along with the Ford VECI label Vehicle Emissions Control Information VECI Labels ROUSH INDUSTRIES VEHICLE EMISSIONS CONTROL INFORMATION Conforms to regulations 2011 MY iNCOMPLETE LPG Weight limits refer to Emission Certification only DO NOT EXCEED VEHICLE GVWR See Incompiete Vehicie Manual U S EPA T28F VI Ire opp CAU L AN V kl GEAR L California SULL et awa ll OBD CA Fuel LPG Completed Vehicle Maximums GVWR 9605 max CurbW 6949s max Frontai Area 60 0 ft2 max No adjustments needed TWC HO2S SFI HAFS 5 4L Group BRIITO5 45HK L Evap BRIIFO265LPG Meesch Figure 1 ROUSH CleanTech VECI Label Typical Ford Motor Company VEHICLE EMISS QN CONTROL INFORMATION Conforms to regulations 2008 MY FFV U S EPA IT2B8 LDT4 OBD Fil A w EL California y TWE HO2S SFI No adjustments needed 5 4L Group 8FMXTO5 44HF Evap 8FMXRO250NBR 78W7E 9C485 R RL SAMPLE Figure 2 Ford VECI Label Typical 2 11 2011 4 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement VECI Label Location The ROUSH CleanTech VECI label appears along with the original Ford VECI label in the following location
30. ation and use of liquefied petroleum gas LP Gas or LPG The book is known as NFPA 58 It is revised as necessary and published every other year This code is adopted as law in virtually every political subdivision in the United States Check with your local authorities for regulations applicable to liquid propane Alert Messages The following alert messages appear from time to time inappropriate places in this manual Ensure that all personnel in the immediate area are aware of these reminders AA Danger Although propane is nontoxic nonpoisonous has the lowest flammability range of any alternative fuel and dissipates quickly when released into the atmosphere propane vapor is heavier than air and seeks the lowest point When the ratio of propane to air is between 2 2 and 9 6 propane will burn in the presence of an ignition source at 940 F 504 C or hotter Keep away from heat sparks flames static electricity or other sources of ignition Failure to heed this danger may result in severe personal injury or death A Danger The fuel supply lines remain pressurized after engine shutdown Keep away from heat sparks flames static electricity or other sources of ignition Do NOT enter storage areas or confined space unless they are adequately ventilated Failure to heed this danger may result in severe personal injury or death A Danger Do NOT carry lighted smoking materials or smoke while working on fuel system components Failure to he
31. ch E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement All ROUSH CleanTech LPA vehicle fuel tanks regardless of configuration are fitted with the same valve assemblies and control units These include the Multivalve assembly Fuel Control Solenoid integrated in FRPCM Fuel Fill Solenoid 80 Level Sensor Fill Pressure Switch and the Fuel Level Sending Unit Multivalve Wiring Pass Through Overpressure Relief Manual Shutoff Fuel Fill K Supply Solenoid Fuel Return Fuel Supply to Engine Figure 9 Multivalve Assembly The Multivalve attaches directly to the fuel tank and serves as the main interface between fuel tank and vehicle As the name implies the Multivalve consists of a number of valves incorporated into one unit The included valves are Fill Valve Located where fuel enters into the fuel tank the fill valve is opened electrically by the Fuel Fill Solenoid during the fill process It also incorporates double back redundant check valves which close when vehicle tank pressure is greater than pressure outside of tank to prevent fuel from escaping Manual Shutoff Valve This manually operated valve is used to seal the outlet of the tank during shipping or service It should always be open when the vehicle is operating Excess Flow Valve The excess flow valve is located in the supply fuel path The valve is intended to shut off fuel flow from the tank in case the supply line co
32. ch will not close and will prevent the tank from filling NO RESTRICTIONS OR PLUGGED FILTER Call ROUSH CleanTech Warranty at 1 800 59 ROUSH RESTRICTIONS AND OR PLUGGED FILTER Repair as necessary and retest 2 11 2011 23 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Slow Fill Condition 1 VERIFY VEHICLE BATTERY IS FULLY CHARGED AND CONNECTED Check battery connections and charge repair as required Attempt to fill vehicle fuel tank as necessary Go to Steps as necessary 2 VERIFY THAT FILL STATION PRESSURE IS AT LEAST 50 PSI GREATER THAN VEHICLE TANK PRESSURE Preliminary check If this is the first fill after vehicle assembly or major fuel system repair follow ROUSH CleanTech service Flush and Fill Procedure for New Tank Note If fill is EXTREMELY slow less than 0 2 gallons per minute and fill station pressure is acceptable 550 PSI over tank it may indicate that the fill circuit is not activated Follow No Fill Condition diagnostic Procedure 1 Attach pressure gauge 350 psi minimum to bleeder valve on vehicle fuel tank 2 Compare tank pressure reading to fill station pressure 3 Record vehicle tank and fill station pressure readings for reference Note Fill station pressure must be at least 50 psi greater than tank pressure If not fuel tank may not fill or will fill slowly 50 PSI OR MORE THAN LESS THAN 50 PSI TANK PRESSURE A
33. cover and attach the 90 degreee elbow to the pressure relief valve on the cover Ensure that the elbow is tight and leads to the driver s side of the vehicle A Caution Hand tighten the 90 degree elbow to avoid cross threading Failure to heed this caution can result in component damage 2 11 2011 43 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Note When installing the 90 degree elbow and brass tube to the Multivalve use anti seize on the threads prior to assembly 3 Install the pressure relief hose if applicable to the 90 degreee elbow and attach the spring clamp 4 Install the negative battery cable Disable the ignition and crank the engine to purge the fuel lines DO NOT START the engine 5 With Snoop or similar product leak check the injectors fuel rails and lines Repair as necessary 6 Start and run the engine and check for diagnostic trouble codes Repair as necessary Any questions please contact ROUSH CleanTech Customer Service at 1 800 597 6874 Fuel System Component Removal Procedures Removing Pressure Relief Hose 1 If applicable disconnect the pressure relief hose from the outlet nozzle bracket at the inner rear fender support Constant tension clamp here Figure 24 Pressure Relief Hose Lower Connection 2 Disconnect the pressure relief hose from the 90 degree elbow in the Multivalve cover 2 11 2011 44 ROUSH CleanTech E 15
34. ct sunlight or vehicle has been run for an extended period of time Cool tank down or try to fill at a time of day when the vehicle and fuel tank have had a chance to cool down Note The fuel tank should fill normally when tank pressure is much lower than fill station pressure 2 11 2011 19 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 4 VERIFY THAT THERE IS 12 VOLT BATTERY POWER TO FUEL TANK FILL CIRCUIT AND POLARITY IS CORRECT Procedure Turn the ignition switch to the off position if not already done Disconnect the 6 wire fuel tank harness connector located on wire loom from fuel tank from the vehicle harness Connect a voltmeter positive lead from the Blue wire Pin A positive and the negative lead to the plain Black wire Pin D negative on the vehicle side of the 6 wire connector or utilize the Fuel Tank Breakout Box see guide provided with the breakout box Check the voltmeter reading The voltmeter should indicate battery voltage 12 volts and also indicate proper polarity 12 VOLTS PRESENT 12 VOLTS NOT ACROSS PIN A AND PIN D PRESENT AND POLARITY IS CORRECT Check 5 or 15 amp fuse in half fuse box located Go to Step 6 under hood driver s side FUSE OK FUSE BLOWN Check for 12 volt supply Go to Step 5 to fuse box SUPPLY CIRCUIT SUPPLY CIRCUIT OK OPEN Check for open circuit Refer to schematic and both positive and repair circuit as
35. e EES EENS EEN 8 Injection Pressure and Temperature Sensor IPTS u J J J 9 Fuel Supply and Return TTT 10 NI ee E E EE E 10 M l valve ni ce ce cee ae p CDU DD EE 11 Fuel Level Sending UE 12 Fuel Filler Valve and ls UNI 12 FEL VALVE E 13 IN LINE FULT BPR EE 13 GOSS ANY e An 13 GOMPRONENT EOCAFPO Ba kole kr bef osi ai oak al kk e a af kk k a ka k ki kk e fk a a kk a e n 15 Engine e une E unn k a n A ok e n kk T 15 Fuel Rail Pressure Control Module FRPCM Rails and Injectors 15 2 11 2011 i ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement CDS SIS erotica ie LOW D E VENE UERBO LR ER LARGEUR RM EO W 16 Fuel Lines and Tank u uuu P m 16 TROUBLESHOOTING ou RE 17 zy uong lu mee 17 Fuel OG OP s M 17 Diagnostic Flow Charts usa e P 18 NO Fill COMI x DLL CR a Q u a sh ad yu Shu 18 Slow Fill Condition aii tea x ete 24 No Start ConditlOn 4 A iLLCLLLLLnLLLLLLLnLL5LLLinLL52LhLihnLs2LinihizLhag ness 26 Fuel Pump Diagnostics 27 Fuel Sending Unit Diagnostics 1 U U u u u u J J
36. e LPA System Bleed and Fill Procedure or follow the fuel tank documentation for the tank bleed and fill procedure If there is no information provided with the tank please contact ROUSH CleanTech Customer Service at 1 800 597 6874 31 With Snoop or similar product leak check the injectors fuel rails and lines Repair as necessary 32 Start and run the engine and check for diagnostic trouble codes Repair as necessary Any questions please contact ROUSH CleanTech Customer Service at 1 800 597 6874 2 11 2011 70 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Fuel System Component Installation Procedures Each of the following installation procedures is complete If two or more procedures are required they can be performed in any convenient order Before Installing Components 1 Ensure that the battery is disconnected 2 Ensure that the ignition key is removed 3 Ifthe fuel tank is installed ensure that the manual shutoff valve on the Multivalve is closed p EY SHUTOFF EP VALVE Figure 67 Manual Shutoff Valve Later Applications 2 11 2011 71 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Installing Injection Pressure and Temperature Sensor 1 Install the Injection Pressure and Temperature Sensor IPTS into the left side fuel rail Figure 68 Injection Pressure and Temperature Sensor 2 C
37. e of HD 10 or other substandard propane may result in excess contamination of the system and failure of the fuel pump injectors and in tank filter A pump inside the tank delivers liquid propane to the injectors through the fuel supply line and the fuel rails Excess fuel flows back to the tank through the fuel return line Fuel pressure is regulated by the Flow Control Solenoid FCS which includes a small orifice to restrict return flow in normal conditions and a bypass circuit to allow maximum fuel flow prior to engine starting or during extremely hot conditions The FCS is integrated into the Fuel Rail Pressure Control Module FRPCM in E Series applications In order to safely store pressurized liquid propane in the vehicle the fill system must ensure that the tank is not filled beyond 8096 of its total volume This ensures that sufficient expansion volume is present in case of significant tank temperature changes 2 11 2011 6 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement The fuel fill system includes the following components Fuel fill valve cap and mounting bracket Fuel fill hoses Fuel fill filter Fuel tank internal components a Fuel fill solenoid b Fill pressure switch c 80 level sensor AON During a fill event the system functions as follows 1 Customer connects fuel filler nozzle to fill valve and activates the fuel pump 2 Fuel pressure in the fill line causes the pressure
38. e personal injury or property damage 1 Close the manual shutoff valve on the tank 2 Disconnect the fuel fill line at the fuel filter Attach Fuel Fill Line to Fuel Filter Torque to 41 49 Nm Figure 29 Fuel Fill Line Filter to Tank 2 11 2011 47 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 3 Remove the fuel tank to gain access to the fuel fill line on the tank 4 Disconnect the fuel fill line Removing Fuel Filler Neck A Danger A trace amount of propane fuel will be released when loosening the fittings Propane settles to the lowest available surface before it dissipates into the atmosphere Keep heat sparks flames static electricity or other sources of ignition out of the area when venting or purging the fuel lines or tank Failure to heed this danger can result in severe personal injury or property damage Figure 30 Fuel Filler Door and Valve with Cap 1 Disconnect the fuel fill line at the fuel filler neck 2 Remove the bolts holding the fill valve and the fuel filler neck to the vehicle side panel 3 Remove the bolts attaching the fuel filler neck inside the fuel filler door 4 Remove the fuel filler neck Figure 31 Fill Valve and Fuel Filler Neck Mounting Bracket 5 Remove the fill valve to mounting bracket nut and separate the valve from the bracket 2 11 2011 48 ROUSH CleanTech E 150 E 250 E 350 Liquid Propa
39. ear 0 amps the fuel fill circuit is not activated and tank will not fill AMMETER READS 0 7 0 95 AMMETER READS NEAR 0 AMPS AMPS OR INTERMITTENTLY DROPS CLOSE TO 0 AMPS Call ROUSH CleanTech Warranty at 1 800 59 ROUSH Check fuel fill electrical circuit repair as required and retest 2 11 2011 25 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement No Start Condition 1 VERIFY VEHICLE BATTERY IS FULLY CHARGED AND CONNECTED Go to Steps as necessary Check battery connections and charge repair as required Attempt to fill vehicle fuel tank as necessary PCM COMMUNICATION Document and record DTC s Verify 12 volt battery Review DTC chart for possible power Verify connections cause and repair direction Inspect DLC connector and check Repair as needed and E Series Fuse F33 SJB and all retest power fuses for power Note Fuse 33 provides power to the FRPCM from Trailer Brake Controller Verify Scan Tool cable and Inspect circuits for connections Connect the Scan Tool to FRPCM and TBC aux power 2 11 2011 26 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Fuel Pump Diagnostics 1 VERIFY VEHICLE BATTERY IS FULLY CHARGED AND CONNECTED Check battery connections and charge repair as required Attempt to fill vehicle fuel tank as Go to Steps as necessary necessary 2 GENERAL INFORMATION The fue
40. ed this danger could result in severe personal injury or death A Danger Disconnect the battery ground at the battery to ensure that the vehicle electrical system has no current Failure to heed this danger could result in severe personal injury or death 2 11 2011 2 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Installation Garaging and Training Chapter 11 of NFPA 58 applies to engine fuel systems using LP Gas in internal combustion engines including containers container appurtenances carburetion equipment piping hose and fittings and their installation Additionally this chapter applies to garaging of vehicles and to the training of personnel Paragraph 11 2 specifies that each person engaged in installing repairing filling or otherwise servicing an LP Gas engine fuel system shall be trained Contact the Propane Education and Research Council to learn more about their CETP E Learning computer based training program stuart flatow propanecouncil org or vincent sibilia propanecouncil org Purging and Venting Tanks and Lines Venting of LP Gas to the atmosphere is covered by paragraphs 7 3 1 General and 7 3 2 Purging of NFPA 58 2008 edition Refer to NFPA 58 Local Codes and Proper Training for specific information relating to safe venting of LPG 2 11 2011 3 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement VEHICLE INFORMATION Build D
41. eleasing the vapor to the atmosphere would be wasteful unsafe and an extremely slow procedure without special equipment It is suggested that a local certified propane handling company be engaged to purge the fuel tank and recapture the fuel as the need requires Purging System Fuel Lines 1 Disconnect the 4 pin electrical connector at the frame rail on the driver s side near the fuel tank Note This disconnects the power to the fuel pump 2 Start the engine and let it run until it stalls Note This purges the supply and return fuel lines of propane 3 Turn off the ignition 2 11 2011 41 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 4 Disconnect the negative battery cable from the battery Manual Fuel Shutoff Note This procedure ensures that no propane leaves the fuel tank during service activity A Warning Care must be taken while working with liquid propane All steps must be followed to prevent personal injury and component damage 1 With the engine turned off remove the negative battery cable from the battery 2 If applicable remove the spring clamp and pressure relief hose from the 90 degree elbow on the Multivalve cover Figure 22 Spring Clamp and Pressure Relief Hose 3 Remove the 90 degree elbow from the pressure relief valve on the Multivalve cover turn counter clockwise and remove the cover Note Some applications have a nut u
42. elieve excessive pressure inside of the vehicle fuel tank The valve is part of the Multivalve Return Solenoid Open when the engine is running the return solenoid allows fuel from the fuel rails to return to the vehicle fuel tank The solenoid remains open for approximately 15 seconds after the engine is turned off allowing pressure in the fuel rails to return to the vehicle fuel tank The solenoid is part of the FRPCM Fill Valve Serves as the fuel fill inlet to the vehicle fuel tank for attachment of the fill station hose The valve is a one way single back check valve that opens during the fuel fill process and closes when fueling is complete to minimize fuel from escaping Supply Solenoid Solenoid that is open energized when the engine is running allowing fuel to flow from the vehicle fuel tank to the fuel rails The solenoid is closed when the engine is turned off preventing fuel from flowing from the vehicle fuel tank to the fuel rails The solenoid is part of the FRPCM Smart Relay Module Module that controls the actuation of the four solenoid valves in the fuel rail pressure control module 2 11 2011 14 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement COMPONENT LOCATOR Engine Compartment Fuel Rail Pressure Control Module FRPCM Rails and Injectors Je RAIL ASSEMBLY SYSTEM FLOW PATH A FRPCM INLET FROM FUEL TANK B FUEL OUTLET TO RH RAIL C
43. emoving Under Vehicle Tank U U u u u uu nnns J J 54 Fuel Tank Installation Procedures u T 61 LPA System Bleed and Fill Procedure U U u u u J 61 Installing Under Vehicle Tank U U U u u u uuu u J 61 Fuel System Component Installation Procedures 71 Before Installing Components I U U u u u u J 71 Installing Injection Pressure and Temperature Sensor J J 72 Installing Fuel Injector U U U u u uu u u u u 72 Installing Right Passenger s Side Fuel Rail U u u u J 72 Installing Left Driver s Side Fuel Rail 1 73 Installing Fuel Filter Assembly IU U U uu u u uuu u J 75 Installing Fuel Filler Neck rre rone Uu u u 76 Installing Fuel Fill Line Filler Neck to Filter
44. fill line to the filler neck ka B pee Mn km M Figure 77 Fuel Fill Line 2 Connect the fuel fill line to the inlet end of the fuel filter and tighten to the specified torque 3 Install new cable ties as needed to secure the fuel fill line 4 If no additional assembly is required open the manual shutoff valve and replace the Multivalve cover 90 degree elbow and pressure relief hose if applicable 5 Connect the battery Installing Fuel Fill Line Fuel Filter to Tank 1 With fuel tank removed for access thread the fuel fill line fitting to its port on the tank and tighten to the specified torque 2 Install the fuel tank and position the fuel fill line for correct routing 2 11 2011 77 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 3 Connect the fuel fill line securely to the outlet end of the fuel filter and tighten to the specified torque Figure 78 Fuel Fill Line Filter to Tank 4 If no additional assembly is required open the manual shutoff valve and replace the Multivalve cover 90 degree elbow and pressure relief hose if applicable 5 Connect the battery Installing Fuel Lines Tank to Engine Note The fuel supply and fuel return lines quick connected into the fuel tank Multivalve are serviceable only with the fuel tank removed 1 Route the forward fuel lines along the frame rail and into position for installation
45. flow from the vehicle fuel tank to the fuel rail The supply solenoid is closed when the engine is turned off preventing fuel from flowing from the vehicle fuel tank to the engine fuel rail Note There is a second supply solenoid located at the fuel tank which prevents fuel from flowing into the chassis fuel lines when the engine is turned off Return Solenoid Open when the engine is running the return solenoid allows fuel to return from the fuel rails to the fuel tank The solenoid remains open for approximately 15 seconds after the engine is turned off allowing pressure in the fuel rails to return to the fuel tank 2 11 2011 8 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Flow Control Solenoid The flow control solenoid is located in the return line During normal engine operation the solenoid is closed which inserts a metered orifice in the fuel return path This results in increased pressure at the fuel rail similar to a conventional pressure regulator Prior to and immediately following engine start and in extremely hot fuel conditions the FCS opens which removes the orifice and allows higher flow rate to flush fuel through the rail Bleed Solenoid Closed when the engine is running the bleed solenoid seals the fuel rail from the vehicle EVAP system After the engine is turned off for approximately one hour the bleed solenoid opens for a calibrated length of time allowing
46. ght Side Fuel Rail 2 Connect the crossover fuel line to the right side fuel rail and tighten to the specified torque w ECK de q TT a J Th eg Sat Se Figure 70 Crossover Fuel Line 3 Connect the fuel supply line at the rear end of the right side fuel rail 4 Connect the fuel injector electrical connectors 5 Connect the PCV hose to the throttle body elbow 6 If no additional assembly is required open the manual shutoff valve and install the Multivalve cover 90 degree elbow and pressure relief hose if applicable 7 Connect the battery Installing Left Driver s Side Fuel Rail A Caution Hand tighten all fuel line connectors and fasteners before applying a wrench to avoid cross threading Failure to heed this caution can result in component damage 1 Assemble and lubricate new O rings on the fuel injector tips 2 Position the left side fuel rail assembly with injectors onto the driver side of the intake manifold and fully seat the injector nozzles A Caution Make sure the fuel injectors are correctly aligned with the intake manifold before seating Failure to heed this caution can result in component damage 2 11 2011 73 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 3 Install and tighten the fuel rail bolts to the specified torque D UE TO 9o m FN IES AT J Ce 1 ki L d bm ers A ur i x fani al xy PT F lt
47. ground in wire harness necessary from fuse box to fuel tank 6 pin connector OPEN NOT OPEN Call ROUSH CleanTech Repair circuit as Warranty at necessary 1 800 59 ROUSH 2 11 2011 20 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 5 CHECK FOR SHORT CIRCUIT IN 12 VOLT SUPPLY TO FUSE BOX Procedure 1 Verify ROUSH CleanTech wire harness isn t damaged 2 Pin out to make sure short isn t in the harness HARNESS OK HARNESS DAMAGED Unplug F Series Flow Control Solenoid FCS or E Series Fuel Rail Pressure Repair harness and Control Module FRPCM retest Does short go away with FCS or FRPCM unplugged Unplug 6 pin fuel tank connector Is there a short in circuit from fuse box with connector unplugged Replace solenoid or pressure control module NO FAILURE IN TANK Locate and repair Call ROUSH short in harness CleanTech Warranty at 1 800 59 ROUSH 2 11 2011 21 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 6 VERIFY THAT THE 6 PIN FUEL TANK CONNECTOR AND HARNESSES TO THE FUEL TANK ARE UNDAMAGED AND OK Visual Inspection Are terminals in the tank side of the 6 pin connector straight and properly positioned Are wires between connector and fuel tank undamaged and in good condition Do wire color codes match on both vehicle and tank side of all connectors from the fuse box to the fuel tank Check that a
48. hicles Fuel Return Check Valve Ensures fuel does not escape from vehicle tank if there is a leak in the fuel return line external to the tank The valve is part of the Multivalve 2 11 2011 13 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Fuel Supply Valve Opened electrically by the Fuel Control Solenoid to provide fuel to the engine Also incorporates an excess flow control valve to minimize fuel escaping if there is a leak in the fuel supply line external to the tank The valve is part of the Multivalve Injection Pressure and Temperature Sensor IPTS Mounted on the fuel rail the IPTS is used to monitor pressure and temperature of the fuel Manual Shutoff Valve Manually operated valve that is used to seal the outlet of the vehicle fuel tank during shipping or service The valve should always be open when the vehicle is operating The valve is part of the Multivalve Multivalve Mounted directly on the vehicle fuel tank and serves as the main interface between fuel tank and vehicle The Multivalve consists of five valves incorporated into one unit which includes the Fill Valve the Manual Shutoff Valve the Pressure Relief Valve the Fuel Supply Valve and the Fuel Return Check Valve Also attached to but not part of the Multivalve are the Fill Pressure Switch and the Fill Control Solenoid which are both internal to the tank Pressure Relief Valve Automatically opens to r
49. ht IPTS Interface Module Screw Snug Tight Multivalve Cover M24 Nut Snug Tight Multivalve to Tank M6 Screw 5 5 49 Fill Valve and Bracket Assembly M5 Bolt 5 7 44 62 Fill Valve to Bracket Nut Snug Tight Pressure Relief Outlet Nozzle Bracket 20 30 15 22 Transmission Dipstick Bracket M6 Bolt 8 12 6 9 2 11 2011 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement SCHEMATICS Fuel System Flow Diagrams Fuel Flow FUEL RAIL TEMP PRESS FUEL TANK FUEL EXCESS SUPPLY MANUAL SUPPLY SHUTOFF SHUTOFF CONTROL FUEL SOLENOID VALVE VALVE PUMP SUPPLY LINE PRESSURE RELIEF HOSE FC1 FILL RECEPTACLE FILTER 2 11 2011 85 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Electrical Wiring Diagrams Wiring Harness Electrical Diagram o c 5 o O L oto o o DTB a C o E c OD o c o c O o Ec O oO O D OO r ee P Ro T I I I I3AWOuD I I NYHL SSVd I I I 1 I j NOLLO3NNOO dWNd 3nd LNO JANW d m 9 i NOLLOSNNOO SS3NHVH AGOS y P A l I a avan IEP NOLLOJNNOO 990900 i i gt SOVAYALNI l NNVL Td VH N LLSSNNGS l JHOMLIN NYO iA FoIAYaS AdO8 I j T I I I I e be il l vetro EE VEIT e E HET wer S AE Se Wwe Wc ia aqu ne I LI l NOLLO3NNOO pom N e j Sidi tive Tans wi A VE Keele ME ee sea oce RON T xoa asna I W e E 3 I
50. j 2 I 4 gt I OD 42 iy l A aNnou5 A O l 8 BH FALISOd AtFliva NOLLO3NNOO I SINGOW Sodus zm See 1 anaow eege c C c io C e e C 3OV3H31NISIdI l l c o Oc EO ce D LI coo UI O O I N ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement In Tank Wire Harness AHOLIMS FYASSIYJ 39vo8L31IHWMOTI3SA 6 AGION31OS Alddns 39vo9ia3iHNWNMONHS 8 A dIONJJOS Aldd NAS _39Y9 9L AVIIANId 7 A YOSNIS 08 dovogianig uvad 9 PHA dd Wd 13n3 FDVI ZL HIVTMANId S AdWndT1and JOVOZI 3iiHWNMOSS AuosNas 08 3dovogi xovig A YSONSS T3A311304 a39vosraiHWMOTl3A Z A YSONSS mAa3113nd 39v938L39Nvuo ovig LIN OHIO NOLL de ON JANM 87 2 11 2011 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement TOOLS AND EQUIPMENT Special Tools Fuel Pressure Gauge Kit 0 500 psi Safety Glasses 2 11 2011 88 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Eyebolt and 5 8 11 Locknut RES Gloves Approved for Propane Leak Detector Liquid Leak Detector 2 11 2011 89
51. l fill line Removing Left Driver s Side Fuel Rail Purge the propane from the fuel lines Disconnect the Mass Air Flow sensor electrical connector Remove the throttle body inlet hose Disconnect the heated PCV hose from the intake manifold ga gt f n Disconnect the Injection Pressure and Temperature Sensor IPTS electrical connector Figure 34 Injection Pressure and Temperature Sensor and Fuel Rail 6 Disconnect the fuel injector electrical connectors 7 Disconnect the fuel crossover fuel line 8 Disconnect the fuel return line at the rear end of the fuel rail 2 11 2011 50 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Note In later applications the fuel supply and fuel return flow to the fuel rails is configured in parallel rather than in series The Fuel Return Line and Tee Assembly connects the two fuel rails at the front with a tee connection to the FRPCM return fuel port The Fuel Supply Line and Tee Assembly connects the two fuel rails at the rear with a tee connection to the FRPCM supply fuel port 9 Remove the fuel rail with injectors Removing Right Passenger s Side Fuel Rail 1 Purge the propane from the fuel lines a Z t3 94095 0 X REMONW YOR KING SSS Figure 35 Fuel Rail with Schrader Valve 2 Disconnect the PCV hose from the throttle body elbow 3 Disconnect the fuel injector electrical connect
52. l pump should run continuously when the engine is cranking or running The ROUSH CleanTech fuel pump relay in the mini relay box is controlled by the original Ford fuel pump circuitry including the Fuel Pump Driver Module and the Inertia Switch or Fuel Pump Interrupt software It is virtually the same as the production Ford circuit except for the addition of a separate fuel pump relay fuel pump fuse and ROUSH CleanTech wire harness to the fuel pump To verify that the fuel pump is operating properly use the following procedure starting with Step 3 3 CHECK FUEL PUMP OPERATION Procedure 1 Turn ignition switch to start position and wait for engine to crank 2 Listening closely at fuel tank can fuel pump be heard running when the engine cranks NO NOT CERTAIN Go to Step 5 Go to Step 4 2 11 2011 27 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 4 CHECK FUEL PUMP PRESSURE Procedure 1 Connect pressure gauge 350 psi min to bleeder valve on fuel tank 2 Open bleeder valve and record gauge pressure reading for reference 3 Close bleeder valve 4 Using propane safe gloves and wearing safety glasses carefully disconnect pressure gauge from bleeder valve making sure to relieve pressure in gauge hose very slowly Connect pressure gauge 350 psi min to fuel rail Turn ignition switch to start position wait for engine to crank Measure pressure at fuel rail when engine begins
53. le place to put the fuel tank so that it can be worked on after being removed from the vehicle The tank might also require temporary storage in preparation for shipment Note Close the manual shutoff valve to ensure that no propane leaves the fuel tank during service activity 4 Warning Care must be taken while working with liquid propane All steps must be followed to prevent personal injury and component damage 1 Purge the propane from the fuel lines 2 With the engine turned off remove the negative battery cable from the battery 2 11 2011 54 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 3 If applicable remove the spring clamp and pressure relief hose from the 90 degree elbow on the Multivalve cover Secure the pressure relief hose out of the way Figure 40 Spring Clamp and Pressure Relief Hose 4 Remove the 90 degree elbow from the pressure relief valve on the Multivalve cover turn counter clockwise and remove the cover Note Some applications have a nut under the 90 degree elbow that must be removed prior to removing the cover A Caution If the 90 degree elbow or nut and tube assembly spins and cannot be removed STOP and contact ROUSH CleanTech Customer Service at 1 800 597 6874 5 With the cover removed locate the manual shutoff valve Turn the manual shutoff valve clockwise until it stops The propane supply from the tank is now shut off
54. line Workshop Manual and wiring diagrams 2 11 2011 31 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 9 CHECK MANUAL VALVE OPERATION Procedure 1 Visually check the valve setting 2 ls the valve control knob set in the open or closed position Note Valve knob turned full counterclockwise is open FULL OPEN FULL CLOSED Check supply line fuel tank to Turn knob counterclockwise until fuel rail for damage causing valve is fully open and retest restrictions and leaks NOT OK Repair or replace line and retest Remove fuel supply solenoid and check resistance should be 12 14 ohms 12 14 OHMS NEAR 0 OHMS Solenoid shorted Using Scan Tool check for Diagnostic Trouble Replace solenoid and Codes DTC s retest POO9E OTHER DTC s NO DTC s WELL ABOVE 14 Solenoid open Refer to FRPCM Repair according to Ford Call ROUSH CleanTech Workshop Manual and Warranty at 1 800 59 ROUSH Diagnosis in this service guide retest 2 11 2011 32 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Fuel Sending Unit Diagnostics 1 VERIFY VEHICLE BATTERY IS FULLY CHARGED AND CONNECTED Go to Steps as necessary Check battery connections and charge repair as required Attempt to fill vehicle fuel tank as necessary 2 VOLT POWER TO FUEL SENDING UNIT Figure 15 6 Pin Harness Connect
55. ll wire crimps are made properly and that there are no loose connections CONNECTOR AND HARNESSES OK DAMAGED LOOSE OR IMPROPERLY PINNED WIRES Repair as required and retest Go to Step 7 7 RECONNECT 6 PIN CONNECTOR AND MEASURE CURRENT TO TANK FILL CIRCUIT Refer to wire harness drawing in Section 9 SCHEMATICS specific to the vehicle you are diagnosing Locate the 5 amp E Series or 15 amp F Series fuse for the fill circuit Procedure 1 Remove 5 amp or 15 amp fuse from mini fuse holder in half fuse box under hood driver s side 2 Connect an ammeter across terminals in fuse holder 3 Attempt to fill tank while watching ammeter Fill circuit will only activate when pump pressure is supplied to the filler Note Ammeter should read 0 7 0 95 amps if fuel fill circuit is activated If ammeter reads near 0 amps the fuel fill circuit is not activated and tank will not fill AMMETER READS 0 7 0 95 AMPS Call ROUSH CleanTech Warranty at 1 800 59 ROUSH AMMETER READS NEAR 0 AMPS Go to Step 8 2 11 2011 22 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 8 CHECK FOR RESTRICTIONS IN THE FUEL FILL SYSTEM Procedure 1 Check for kinks or restrictions in the tank blue fill hose 2 Verify that the fuel filter is not plugged 3 Verify that the Fill Valve is functioning properly Note If any of the above problem conditions exist the fuel fill swit
56. mes off of the tank If the excess flow valve trips may happen after servicing the system it can be reset by closing the manual shutoff valve and then slowly opening it Pressure Relief Valve When conditions cause tank pressure to rise to 312 psi this valve automatically opens to relieve the excessive pressure inside of the vehicle fuel tank Propane vapor is vented out of the pressure relief hose 2 11 2011 11 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Fuel Supply Valve The fuel supply valve is controlled by the PCM and is activated whenever power is supplied to the fuel pump Fuel Return Check Valve The fuel return line is protected by a check valve in the Multivalve which prevents fuel from flowing from the tank into the return line Fuel Level Sending Unit The Fuel Level Sending Unit is located inside of the fuel tank and consists of a float on an arm with a wound resistor The sending unit resistance is used by the instrument cluster to indicate fuel level and by the PCM It is not used in the fill system Fuel Filler Valve and Fill Line The fuel fill line includes the fuel port with fill valve the fill line hose and a fuel filter AN a K HZ Figure 10 Fuel Filler Neck Fill Line and Fuel Filter 2 11 2011 12 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement FILL VALVE The Fill Valve serves as the fuel fill inle
57. nder the 90 degree elbow that must be removed prior to removing the cover A Caution If the 90 degree elbow or nut and tube assembly spins and cannot be removed STOP and contact ROUSH CleanTech Customer Service at 1 800 597 6874 4 With the cover removed locate the manual shutoff valve Turn the manual shutoff valve clockwise until it stops The propane supply from the tank is now shut off 2 11 2011 42 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Note The manual shutoff valve can be hard to turn From fully open to fully closed is approximately 2 1 2 turns Figure 23 Multivalve Assembly 1 Electrical Pass 5 Fuel Filler Inlet Through not Elbow serviceable 6 Fuel Return Line 2 Manual Shutoff 7 Pressure Relief Valve Valve 3 Fuel Supply Solenoid 4 Fuel Supply Line Opening Manual Shutoff Valve 1 After fuel system service is completed open the manual shutoff valve on the fuel tank turning the valve counter clockwise until it stops Make sure to open the shutoff valve slowly Releasing fuel quickly into an empty fuel line can set off a special check valve which could restrict fuel flow Note If difficulty occurs close the manual shutoff valve completely and then open it again slowly Note The manual shutoff valve can be hard to turn From fully open to fully closed is approximately 2 1 2 turns 2 Install the Multivalve
58. ne Autogas 2011 Service Manual Supplement Removing Fuel Filter Assembly A Danger A trace amount of propane fuel will be released when loosening the fittings Propane settles to the lowest available surface before it dissipates into the atmosphere Keep heat sparks flames static electricity or other sources of ignition out of the area when venting or purging the fuel lines or tank Failure to heed this danger can result in severe personal injury or property damage 1 Disconnect the fuel fill line at the filter inlet A Figure 32 Fuel Filter Assembly 2 Disconnect the fuel fill line at the filter outlet 3 Loosen the fuel filter clamp 4 Remove the fuel filter Removing Fuel Fill Line Neck to Filter A Danger A trace amount of propane fuel will be released when loosening the fittings Propane settles to the lowest available surface before it dissipates into the atmosphere Keep heat sparks flames static electricity or other sources of ignition out of the area when venting or purging the fuel lines or tank Failure to heed this danger can result in severe personal injury or property damage 1 Disconnect the fuel fill line from the inlet end of the fuel filter 2 11 2011 49 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 2 Disconnect the fuel fill line from the filler neck EE Figure 33 Fuel Fill Line Typical 3 Remove the fue
59. nition switch to start position release and wait for engine to crank Check voltmeter reading when engine begins to crank Voltmeter should indicate battery voltage 12 volts across the two wires 12 VOLTS 0 VOLTS Check fuel tank wiring harness for damaged wires Go to Step 6 pins or anything that may cause an open circuit HARNESS OK NOT OK Call ROUSH CleanTech Repair harness and Warranty at retest 1 800 59 ROUSH 2 11 2011 29 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 6 CHECK 20 AMP FUSE Figure 14 Half Fuse Box Procedure Visually check to see if the fuse is OK or if it is blown The 20 amp fuse is in the number 2 position in the half fuse box FUSE OK FUSE BLOWN Using voltmeter check for battery voltage 12 volts in supply line at fuse ignition switch in on position engine not running Check for shorts repair circuit and replace fuse Repeat Step 3 12 VOLTS 0 VOLTS Go to Step 7 Using Scan Tool check for Diagnostic Trouble Codes DTC s Repair according to Ford Workshop Manual 2 11 2011 30 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 7 CHECK FUEL PUMP RELAY FUNCTION Check fuel pump relay function per the Ford On line Workshop Manual and wiring diagrams 8 CHECK FUEL PUMP RELAY SUPPLY CIRCUIT Check fuel pump relay function per the Ford On
60. noid will not open to accept more fuel IS FUEL LEVEL IN TANK BELOW 8096 FULL Drive vehicle until low on fuel below 8096 tank capacity and attempt refill Go to Step 3 2 11 2011 18 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 3 VERIFY THAT STATION FILL HOSE IS PROPERLY CONNECTED TO VEHICLE AND STATION IS OPERATING Procedure 1 Connect pressure gauge 350 psi min to bleeder valve on fuel tank 2 Open bleeder valve and record gauge pressure reading 3 Close bleeder valve 4 Using propane safe gloves and safety glasses carefully disconnect pressure gauge from bleeder valve making sure to relieve pressure in gauge hose very slowly 5 Using the Fuel Fill Pressure Tester or equivalent measure fill station pressure 6 Compare fuel tank pressure to fill station pressure Note Fill station pressure must be at least 50 psi greater than the vehicle fuel tank pressure or the tank will not fill FILL STATION PRESSURE FILL STATION PRESSURE IS gt 50 PSI ABOVE FUEL 50 PSI ABOVE FUEL TANK PRESSURE TANK PRESSURE Go to Step 4 FILL STATION FILL STATION NOT FUNCTIONING FUNCTIONING PROPERLY Typically 300 psi or higher Try another station Advise station owner to repair fuel delivery system ROUSH CleanTech recommends 7 5hp pump for liquid automotive fills Vehicle fuel tank may be hot enough to have an excessive amount of pressure if tank has been in dire
61. odel Cab Body Type Wheelbase E 150 Van 138 Cargo Wagon E 250 Van 138 Cargo Wagon E 350 Van 138 Cargo Wagon Note Vehicle dimensions are as quoted in the Ford Owner s Guide except that options are available only as shown in the following table 2 11 2011 83 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Fastener Torque Values Fasteners Fittings and Connections Part Description Name N m Lb Ft Lb In FRPCM to Bracket M6 Bolt 8 12 6 9 FRPCM to Intake Manifold M6 Bolt 8 12 6 9 Fuel Crossover Line Fitting 18 22 13 16 Fuel Fill Hose Fittings at Fill Valve and Fuel 41 49 30 36 Filter Fuel Fill Line Fittings at Fuel Tank and Fuel Filter 41 49 30 36 Fuel Filter and Bracket Assembly M6 Bolt 20 30 15 22 Fuel Filter to Bracket Clamp 4 5 35 44 Fuel Rail Crossover Fuel Line Fitting 18 22 13 16 Fuel Line Support Bracket to Frame M8 Nut 20 30 15 22 Fuel Rail Mounting M6 Bolt 8 12 6 9 Fuel Supply and Return Line Fittings 18 22 13 16 Fuel Lines at FRPCM 18 22 13 16 Fuel Tank Crossmember Mounting Bracket 20 30 15 22 Front Rear M8 Bolt Fuel Tank Crossmember Mounting Bracket 80 90 59 66 Front Rear M12 Nut Fuel Tank M12 Mounting Bolt at Frame Rail 80 90 59 66 Bracket Front Rear Fuel Tank Mounting Bracket at Frame Rail M10 40 55 30 41 Bolt Front Rear Fuse Box to Bracket Screw Snug Tig
62. onnect the battery Installing Fuel Rail Pressure Control Module 1 Position the FRPCM to the mounting location on the left rear of the intake manifold Install the mounting bolts one bolt through throttle body spacer to secure the FRPCM and tighten to the specified torque Remove the rear throttle body spacer fastener and install the FRPCM Re e Ja install this fastener once the M6 x 62 bolts attach module Em f FRPCM is in position to the intake manifold Figure 82 Fuel Rail Pressure Control Module 2 Connect the jumper fuel line to the RH fuel rail and to the lower right port of the FRPCM Connect the Fuel Jumper Line from the FRPCM to the RH Fuel Rail Figure 83 Jumper Line to Fuel Rail 3 Connect the forward fuel return line to the lower left port of the FRPCM Figure 84 Fuel Return Line to FRPCM 2 11 2011 80 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 4 Connect the forward fuel supply line to the FRPCM Figure 85 Fuel Supply Line to FRPCM 5 Connect the jumper fuel line to the LH fuel rail and to the upper left port of the FRPCM Connect the Jumper i Line from the LH Fuel ane Rail to the FRPCM Figure 86 Jumper Line to Fuel Rail 6 Tighten all fuel line connections to the specified torque 7 Place the fuel lines in the retention bracket with sleeves and bend over the crimp
63. onnect the electrical connector to the IPTS Installing Fuel Injector 1 Lubricate the upper and lower fuel injector O rings using SAE 5w20 motor oil or equivalent 2 Install the fuel injector into the fuel rail with a twisting motion so that the electrical connection faces the fender of the vehicle opposite the intake manifold when the injector is fully seated 3 Install the fuel injector hold down bracket and bolts Tighten the fasteners to 3 Nem 27 Ib in Install the fuel injector electrical connector 4 Repeat the Removing Fuel Injector steps and Steps 1 3 of Installing Fuel Injector for the remaining fuel injectors as needed Installing Right Passenger s Side Fuel Rail A Caution Hand tighten all fuel line connectors and fasteners before applying a wrench to avoid cross threading Failure to heed this caution can result in component damage Assemble and lubricate new O rings on the injector tips Position the right side fuel rail assembly with injectors onto the passenger side of the intake manifold and fully seat the injector nozzles A Caution Make sure the fuel injectors are correctly aligned with the intake manifold before seating Failure to heed this caution can result in component damage 2 11 2011 72 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 1 Install and tighten the right side fuel rail bolts to the specified torque Figure 69 Ri
64. or Vehicle Side 2 11 2011 33 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Procedure Turn the ignition switch to the off position if not already done Disconnect the 6 pin fuel tank harness connector located on fuel tank wire loom from the vehicle harness On the vehicle side of the 6 pin connector connect positive lead of voltmeter to the Yellow wire Pin E positive and negative lead to the Black Orange wire Pin F negative Check the voltmeter reading The voltmeter should indicate battery voltage 12 volts and also indicate proper polarity 12 VOLTS PRESENT ACROSS 12 VOLTS NOT PRESENT PIN E AND PIN F AND POLARITY OR MUCH LESS THAN IS CORRECT BATTERY VOLTAGE Go to Step 4 Go to Step 3 2 11 2011 34 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 3 CHECK FOR 12 VOLT POWER AT THE 4 PIN CONNECTOR PPM eem Tu S ig A Procedure With the ignition switch in the off position disconnect the 4 pin connector where the ROUSH CleanTech harness attaches to the Ford vehicle harness Using the voltmeter on the Ford harness side of the connector place the positive lead on the Yellow wire terminal and the negative lead on the Black Orange wire terminal Check for battery voltage 12 volts across the terminals 12 VOLTS PRESENT ACROSS YELLOW AND 12 VOLTS NOT PRESENT BLACK ORANGE WIRES OR MUCH LESS THAN AND POLARITY IS BATT
65. ors 4 Disconnect the fuel supply line at the rear end of the right side fuel rail Note In later applications the fuel supply and fuel return flow to the fuel rails is configured in parallel rather than in series The Fuel Return Line and Tee Assembly connects the two fuel rails at the front with a tee connection to the FRPCM return fuel port The Fuel Supply Line and Tee Assembly connects the two fuel rails at the rear with a tee connection to the FRPCM supply fuel port 2 11 2011 51 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 5 Disconnect the crossover fuel line from the right side fuel rail Figure 37 Crossover Fuel Line Later Applications 6 Remove the fuel rail with injectors 2 11 2011 52 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Removing Fuel Injector 1 Locate the fuel rail service port on the right side fuel rail Release the pressure in the fuel rail and lines Figure 38 Fuel Rail Service Port A Caution The fuel rail is under high pressure Care should be taken when releasing pressure to avoid personal injury 2 Disconnect the fuel injector connector remove the fuel injector hold down bracket bolts and remove the bracket 3 Using a twisting motion pull the fuel injector out of the fuel rail a pair of pliers might be necessary to help remove the fuel injector U
66. r Inspection Figure 18 Intake Air Duct and Filter Housing typical This intake air filter assembly is common to base Ford vehicles Consult the appropriate Ford Work Shop Manual for service 2 11 2011 37 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement In Line Fuel Filter Replacement AA Danger A trace amount of propane fuel will be released on loosening the fittings It will settle to the lowest available surface before it dissipates into the atmosphere Keep heat sparks flames static electricity or other sources of ignition out of the area when venting or purging the fuel lines or tank Failure to heed this danger can result in severe personal injury or property damage 1 Purge residual fuel from the fuel fill line 2 Disconnect the fuel fill line from the fuel filter inlet P10C2 9180 AA Orient filter so fuel flow matches the direction of the arrow as shown Figure 19 In Line Fuel Filter Typical 3 Disconnect the fuel fill line from the fuel filter outlet 4 Loosen the clamp retaining the fuel filter in place 5 Remove and discard the filter 6 Place a new fuel filter in position on the filter bracket and tighten the retaining clamp to 4 5 Nem 35 44 Ib in 7 Connect the fuel file lines to the filter inlet and outlet Tighten the line fittings to 41 49 Nem 30 36 Ib ft 2 11 2011 38 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane
67. rated with Ford s One Touch Starting system The vehicle operator turns the key to the Start position and releases it The computer senses the pressure temperature in the fuel lines and starts the fuel pump The pump sends liquid propane through the lines driving the vapor back to the tank to become liquid again When the pressure temperature sensor reports that the lines are full of liquid the computer energizes the starter and the ignition system The entire sequence generally takes from 1 5 to 10 seconds may extend to 20 seconds under extreme ambient conditions Fill Stations Propane is readily available anywhere in the United States To locate the nearest station check with http www afdc energy gov afdc locator stations 2 11 2011 1 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement ROUSH CleanTech recommends facilities designed for automotive refueling Other locations may have low output pumps resulting in slow or no fill or low quality fuel which can result in premature component failure Range and Fuel Economy Propane contains less energy per unit volume then gasoline Therefore customers will generally experience fuel economy mile per gallon 15 30 lower than gasoline Vehicle range will vary based on driving conditions and loading Safety Information The National Fire Protection Association NFPA publishes a code book of rules that apply to the storage handling transport
68. rs attaching the tank to the left frame rail and to the front and rear crossmembers later applications with dual tank use the right frame rail to secure the tank Remove the mounting isolators and crush limiters as necessary Figure 44 Outboard Fuel Tank Mounting Bolt and Washer Figure 45 Crossmember Fuel Tank Mounting Nut and Washer 11 With the help of an assistant lower the tank approximately 12 18 inches to gain access to the fuel tank electrical connector 2 11 2011 58 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement 12 Cut the tie straps and then disconnect the fuel tank 6 pin connector Figure 46 Fuel Tank Electrical Connector Typical 13 Lower the tank from under the vehicle and place it on a suitable surface A Caution Fuel lines remain attached to the Multivalve and can extend below the tank support weldments Ensure that clearance is provided when resting the tank on any surface Failure to heed this caution can result in component damage 14 Detach the hoist and remove the lifting straps 15 Remove the convolute tubing from the fuel lines 16 Remove the convolute tubing from the fuel fill line and the electrical cables 17 Disconnect the fuel supply line and the fuel return line from the Multivalve quick connect supply and return ports Fuel Fill Line P10C2 9047 AA Wiring harness located here removed for clarity Install 350 P
69. se care to prevent damage to the fuel injector As the fuel injector is being removed from the rail make sure that the brass calibrator is still down inside the fuel rail and not on the fuel injector Note The brass calibrator is assembled with the nozzle and screwed into the bottom of the fuel rail Replacing the fuel injector does not require removal of the calibrator and nozzle but in some instances the calibrator can come out of the fuel rail when the fuel injector is removed 4 Repeat Steps 2 3 as needed for the remaining fuel injectors 2 11 2011 53 ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Removing Injection Pressure and Temperature Sensor 1 Purge the propane from the fuel lines Figure 39 Injection Pressure and Temperature Sensor 2 Disconnect the electrical connector from the Injection Pressure and Temperature Sensor IPTS 3 Remove the IPTS from the left side fuel rail Fuel Tank Removal Procedures Purging Fuel Tank A propane fuel tank must be empty of propane before it can be transported by a carrier Due to the volume of fuel likely to be retained in a tank releasing the vapor to the atmosphere would be wasteful unsafe and an extremely slow procedure without special handling equipment It is suggested that a certified propane handling company be engaged to purge the fuel tank as needed Removing Under Vehicle Tank Note Locate a suitab
70. sure relief hose if applicable clamps to an elbow that attaches the cover to the Multivalve The pressure relief hose elbow and Multivalve cover are removable while the tank is in the vehicle The bleeder valve vents immediately to the atmosphere This valve can be serviced using a standard box end wrench while the tank is in the vehicle Later models are equipped with a remote bleeder valve and hose assembly mounted on the frame rail which can be serviced independently Purging Clearing the propane out of the fuel lines purging is required before attempting to remove any of the components Following the suggested techniques for purging will discharge a minimum of the vapor harmlessly into the atmosphere and produce the least risk to life and property Make certain to observe the alert messages They consist of reminders of Dangers Warnings and Cautions Other reminders may appear under the heading Notes Several components attached to the Multivalve on the fuel tank cannot be removed from the Multivalve until after the fuel tank is removed from the vehicle This includes the fuel supply line fuel return line fuel fill line fuel pump control solenoid The electrical harness attached to the tank is a permanent fixture and cannot be removed in the field Purging the Fuel Tank A propane fuel tank must be empty of propane before it can be transported by a carrier Due to the volume of fuel likely to be retained in the fuel tank r
71. t to the vehicle fuel tank This is where the fill station hose attaches while fueling and the fuel cap attaches during vehicle operation It is a one way single back check valve that opens during the fuel fill process and closes when fueling is complete to minimize fuel from escaping IN LINE FILTER The fuel filter is located in the fuel fill line to filter fuel from the fill station before it enters the vehicle fuel tank The filter is field serviceable and should be replaced every 50 000 miles Glossary 80 Level Sensor An infrared sensor designed to detect the presence of liquid The sensor is located inside the vehicle fuel tank at the 8096 full level Bleed Solenoid Closed when the engine is running sealing the fuel rail from the vehicle EVAP system After the engine is turned off for approximately one hour the Bleed Solenoid opens for a calibrated length of time allowing pressure to bleed from the fuel rails When pressure is fully bled off the solenoid closes preventing fuel from entering the EVAP system The bleed solenoid is located in the FRPCM Fill Pressure Switch A normally open pressure sensing switch The switch is attached to the Multivalve internal to the vehicle fuel tank and used to sense pressure of the fuel coming into the vehicle fuel tank from the fill station Fill Valve Located where fuel enters into the vehicle fuel tank During the fill process the valve is opened electrically by the Fuel Fill
72. u m a e ek ak wk J J ll INTRODUCTION ep M 1 General Informati n mL 1 ROUSH CleanTech Technical Assistance U U u u J J 1 Start Sequence ui A aS SS Sua Sau Sasa a Sasu S a Senk sena asus 1 Fill StAWON Ss et 1 Range and Fuel Econony U U U u u u u u u Q J J 2 Safety dni m 2 Alert MeS SageS E RR RE 2 Installation Garaging and Training J U 3 Purging and Venting Tanks and Lines U 3 VEHICLE INFORMATIOLNN nnn nnn J asus aan sees J J nana 4 B lld bir erem E E 4 Vehicle Emissions Control Information VECI Labels 4 VECI Label Locat ON D 5 DESCRIPTION AND OPERATIOLN J ina e a da ea kd kak avan fr Q aera eade 6 System UE 6 Vehicle Starting u c E noon 7 System Components and Function U 8 Fuel Rails and Injectors aa ee
73. ving Fuel Rail Pressure Control Module U U u 45 Removing Fuel Lines Tank to Engine U U u u sene 45 Removing Fuel Fill Line Filter to Tank 1 1 n nn nnn nnns 47 Removing Fuel Filler Neck U u uu mnn asa n nass annnm nasus u J J 48 Removing Fuel Filter Assembly I U U u u uu uu u J 49 Removing Fuel Fill Line Neck to Filter 1 49 Removing Left Driver s Side Fuel Rail J 1L J1 II 50 2 11 2011 ii ROUSH CleanTech E 150 E 250 E 350 Liquid Propane Autogas 2011 Service Manual Supplement Removing Right Passenger s Side Fuel Rail U U u u J J 51 Removing FuelInjector Gu Aa EE EE ENEE 53 Removing Injection Pressure and Temperature Sensor J 54 Fuel Tank Removal Procedures u 54 Purging Fuel Tank uu Lu aha qu au u g e prx Ras qu ua u aaah puasa sqa 54 R

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