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2007.5 - 2008 Ford F-150 LIQUID PROPANE

1. Removing Fuel Lines Under Vehicle Toroidal Tank to Solenoid Removing Fuel Lines Solenoid to Engine Removing Fuel Fill Line Filter to Tank Removing Fuel Filler Ne6K exire eebe Removing Fuel Filter Assembly eeeeeeeeeeeeeeeeeeeeeeenn nennen Removing Fuel Fill Line Neck to Filter eeeeeeeeeeeeeee Removing Left Driver s Side Fuel Rail Removing Right Passenger s Side Fuel Rail REMOVING Fuel IN O COLON eee Removing Injection Pressure and Temperature Sensor Fuel Tank Removal Procedures cceeeeeee Purging Fuel Tank 5 correre uo nri otn a aree eer rn nean e raa e cce ere nena nura a kr eee rrr duis adeae Removitig Iri Bed Tank eege Removing Under Vehicle Toroidal Tank eese Fuel Tank Installation Procedures eee LPG System Bleed and Fill Procedure eeeeeesss Installing Under Vehicle Toroidal Tank eese Installing In Bed Tank aoi ecco rera Rex Lc n ne e eii Dn du ad eii d Fuel System Component Installation Procedures Before Installing Components
2. eeeeeeeeeeeeeeeeeeeeeeeeennnn nnn Installing Injection Pressure and Temperature Sensor Installing Fuel Injector oec iiio sc ex neon ee Diva Rr 020 oo Lua acta ar Rua aba exire a gece Installing Right Passenger s Side Fuel Rail Installing Left Driver s Side Fuel Rail Installing Fuel Filter Assembly eeeeeeereerneeeeeeeerennnnnn Installing Fuel Filler Neck ueitioodisnisindeua bass bia Ride bd ADR ben bx Ko bid bUvE Dvd iere Installing Fuel Fill Line Filler Neck to Filter Installing Fuel Fill Line Fuel Filter to Tank 12 14 2010 Current as of 12 14 201 0 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Installing Fuel Lines Solenoid to Engine eeeereeeeeeeeeeee 84 Installing Fuel Lines Under Vehicle Tank to Solenoid 84 Installing Fuel Lines In Bed Tank to Solenoid 85 Installing Flow Control SOlQNOI eeceeeeeeeeeeeeeeeeeeeeeeeeeseeeseeeeeeeeeeeeeseeeeeeeeeeeeeeees 85 Installing Pressure Relief HOSC ccceecceeeesseseeeeeceeeeeeeeees
3. Figure 89 Fuel Lines Typical 1 Retention Clip 3 Intermediate 2 ntermediate Fuel Return Line Fuel Supply Line 4 Flow Control Solenoid 4 Connect the flow control solenoid electrical connector 5 f no additional assembly is required open the manual shutoff valve and replace the Multivalve cover 90 degree elbow and pressure relief hose TUE Current as of 12 14 2010 di ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 6 Connect the battery Installing Pressure Relief Hose 1 Connect the pressure relief hose to the 90 degree elbow in the Multivalve cover Retain with spring clamp 2 Connect the pressure relief hose to the outlet nozzle bracket at the fender support rod Constant tension clamp here Figure 90 Pressure Relief Hose Lower Connection EE Current as of 12 14 2010 i SPECIFICATIONS ROUSH CleanTech F 150 Liquid Propane Injection 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 3 per cylinder Va
4. Figure 80 Left Side Fuel Rail 4 Connect the fuel return line at the rear end of the left side fuel rail 6 Connect the fuel injector electrical connectors 7 Connect the Injection Pressure and Temperature Sensor IPTS electrical connector Figure 82 Fuel Rail with Injection Pressure and Temperature Sensor 8 Connect the heated PCV hose to the intake manifold 9 Attach the throttle body inlet hose RUE Current as of 12 14 2010 E ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 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 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 Figure 83 Fuel Filter Assembly 5 If no additional assembly is required open the manual shutoff valve and replace the Multivalve cover 90 degree elbow and pressure relief hose 6 Connect the battery Installing Fuel Filler Neck A Caution Hand tighten all fuel line
5. Fuel Tank Mounting Bolts 80 10 59 7 2 Fuel Tank Safety Straps 22 Fuel Tank Safety Tub 2 Ground Strap to Bulkhead Bolt 12 1 9 0 7 12 1 9 10 7 Ground Strap to Rear Cross Member Bolt 9 1 80 9 Ib in 9 1 80 9 Ib in Mass Air Flow MAF Sensor Bolts 6 1 53 9 Ib in 6 1 53 9 Ib in Power Steering Relocation Bracket Bolts 10 2 89 9 Ib in 10 2 89 9 Ib in Power Steering Reservoir Bolts 10 2 89 9 Ib in 10 2 89 9 Ib in Powertrain Control Module Bracket Bolts 7 1 62 9 lb in 7 1 62 49 Ib in Powertrain Control Module to Bracket Bolts 7 1 62 9 lb in 7 1 62 49 Ib in Pressure Relief Outlet Nozzle to J Nut 10 1 89 9 Ib in 10 2 89 9 Ib in Relay Box Bolts 10 2 89 9 Ib in 10 2 89 9 Ib in Rivnut Bolts Throttle Body Studs 10 2 89 9 Ib in 10 2 89 9 Ib in Throttle Body Nuts 10 2 89 9 Ib in 10 2 89 9 Ib in 10 2 89 9 Ib in 10 2 89 9 Ib in 12 14 2010 Current as of 12 14 201 0 88 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Fittings and Connections Torque in Nem Lb Ft Lb In Description In Bed Cylindrical Tank Under Vehicle Toroidal Tank Forward Return Line to Flow Control Solenoid blue tag 21 2 15 1 21 2 15 1 Forwa
6. Insert the tank end of the fuel supply line and the fuel return line through the tank collar 2 Carefully install the wiring harness through the upper right hole of the tank collar grommet 3 Install the fuel fill line through the tank collar 4 Assemble the fuel fill line to the fitting on the Multivalve Support the fitting while tightening the fill line to the specified torque Figure 61 Fuel Fill Line 5 Position the fuel supply solenoid and install the E clip 6 Hand tighten the fuel supply line and the fuel return line into the Multivalve supply and return ports Tighten the lines to the specified torque Wiring harness located here removed for clarity Install 350 PSI Design Pressure Label here emmer A Tt ncm Fuel Supply Line D U u Pd Figure 62 Multivalve Connections 7 Install the convolute tubing onto the fuel fill line and the electrical cables 8 Install the convolute tubing over the fuel supply and return lines RUE Current as of 12 14 2010 x ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 9 Arrange the fuel lines and wiring harness as shown so that the Multivalve cover can be easily installed later Note There is a connector with two wires for engineering diagnostics at this time E Ex npo 3 A TEN Figure 63 Fuel Line and Wiring Arrangement 10 Attach the hoist and the lifting straps to the fu
7. QI e xo I 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 Disconnect the Injection Pressure and Temperature Sensor IPTS electrical connector Figure 41 Injection Pressure and Temperature Sensor and Fuel Rail 6 ro 8 9 Disconnect the fuel injector electrical connectors Disconnect the fuel crossover fuel line Disconnect the fuel return line at the rear end of the fuel rail Remove the fuel rail with injectors ID Current as of 12 14 2010 9d ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Removing Right Passenger s Side Fuel Rail 1 Purge the propane from the fuel lines 073 opas et I REMONW Figure 42 Fuel Rail with Schrader Valve 2 Disconnect the PCV hose from the throttle body elbow 3 Disconnect the fuel injector electrical connectors 4 Disconnect the fuel supply line at the rear end of the right side fuel rail 5 Disconnect the crossover fuel line from the right side fuel rail 77 SEs 6 Remove the fuel rail with injectors 12 14 2010 Cu rrent as of 12 71 4 201 0 54 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Removing Fuel Injector 1 Locate the fuel rail service port on the right side fuel rail Release the
8. Call ROUSH CleanTech Warranty at 1 800 59 ROUSH RESTRICTIONS AND OR PLUGGED FILTER Repair as necessary and retest ID Current as of 12 14 2010 SS ROUSH CleanTech F 150 Liquid Propane Injection 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 gt 50 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 ABOVE TANK PRESSURE Go to Step 2 Has the vehicle been exposed to high ambient air temperatu
9. 150 Liquid Propane Injection Service Manual Supplement Injection Pressure and Temperature Sensor IPTS The IPTS is used to monitor fuel pressure and temperature On F 150 applications the IPTS is read directly by the PCM Figure 7 Injection Pressure and Temperature Sensor 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 _DSC5216 NEF For position only need representative illustration Figure 8 Stainless Fuel Supply and Return Lines Typical TED Current as of 12 14 2010 j ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Fuel Tanks Different tank configurations are used based on the vehicle model A toroidal doughnut shaped tank mounted under vehicle is available for the F 150 LPI vehicle Optional on F 150 models is a large diameter cylindrical tank mounted in the pickup bed The in bed tank with its greater fuel capacity provides extended range Figure 9
10. 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 NO NOT YES CERTAIN Go to Step 9 Go to Step 5 pressure gauge from With engine running disconnect Flow fuel rail making sure to relieve pressure in Control Solenoid FCS and check fuel pressure gauge hose very slowly PRESSURE GOES PRESSURE GOES PRESSURE UNCHANGED HIGHER LOWER FCS energized FCS stuck open replace should not be FCS working properly FCS and retest Check for short in supply circuit to FCS repair and retest ID Current as of 12 14 2010 SS ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 5 CHECK MULTIVALVE SOLENOID ACTUATION Wiring Pass Through Overpressure Relief Manual Shutoff Fuel Fill LE NP O Supply Solenoid e opa Fuel Return Fuel Supply to Engine Figure 14 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 ignition switch to start position release and wait for engine
11. 95 AMMETER READS NEAR 0 AMPS AMPS OR INTERMITTENTLY DROPS CLOSE TO 0 AMPS Call ROUSH CleanTech Warranty Check fuel fill electrical circuit at 1 800 59 ROUSH repair as required and retest RUE Current as of 12 14 2010 2 ROUSH CleanTech F 150 Liquid Propane Injection 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 Controller Verify Scan Tool cable and Inspect circuits for connections Connect the Scan Tool to FRPCM and TBC aux power SS Current as of 12 14 2010 zi ROUSH CleanTech F 150 Liquid Propane Injection 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 fuel pump should run continuously when the engine is cranking or running The ROUSH CleanTech fuel pump relay in t
12. Disconnect the power steering fluid line 4 Remove the reservoir from its pedestal and carefully set it aside for reuse Note The power steering fluid reservoir is a ROUSH CleanTech part It is not interchangeable with the Ford part RUE Current as of 12 14 2010 en ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Installing Power Steering Fluid Reservoir 1 Assemble the power steering fluid reservoir on its pedestal Note The power steering fluid reservoir is a ROUSH CleanTech part It is not interchangeable with the Ford part 2 Tighten the screws to the specified torque 3 Connect the power steering fluid lines Figure 28 Power Steering Fluid Reservoir 4 If no additional assembly is required open the manual shutoff valve and replace the Multivalve cover 90 degree elbow and pressure relief hose 5 Connect the battery Installing Intake Airbox Cover 1 Assemble the three hose clamps on the intake air tubing 2 Protecting the filter element assemble the tube and airbox cover on the airbox Figure 29 Intake Airbox Cover with Filter Element 1 RUE Current as of 12 14 2010 is ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 3 Tighten the clamps to the specified torque la 3 E Figure 30 Hose Clamps 1 2 and 3 Intake Air System 4 If no additional assembly is required open the manual shutof
13. Fuel Tanks Under Vehicle Toroidal and In Bed Configurations All ROUSH CleanTech LPI vehicle fuel tanks regardless of configuration are fitted with the same valve assemblies and control units These include the Multivalve assembly Fuel Control Solenoid Fuel Fill Solenoid 8096 Level Sensor Fill Pressure Switch and the Fuel Level Sending Unit RUE Current as of 12 14 2010 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Multivalve Wiring Pass Through Overpressure Relief Manual Shutoff Fuel Fill Supply Solenoid Fuel Return Fuel Supply to Engine Figure 10 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 p
14. IPTS from the left side fuel rail EE Current as of 12 14 2010 di ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 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 purge the fuel tank as needed Removing In Bed Tank Note Before removing the in bed tank from the vehicle provide a suitable place to put the tank where it can be worked on after removal from the vehicle The tank may also require temporary storage awaiting preparation for shipment 1 Purge the propane from the fuel lines 2 Disconnect the fuel fill line at the inlet of the fuel filter 3 Disconnect the off tank fuel lines from the intermediate fuel supply and fuel return lines Figure 46 Fuel Lines 1 Fuel Supply Line 2 Fuel Return Line 4 Detach the off tank fuel lines from the retention clips TE Current as of 12 14 2010 ot ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 5 Disconnect the pressure relief hose from the outlet nozzle at the fender support rod Constant tension clamp here ei Ut Figure 47 P
15. and Fill Line FILL VALVE The Fill Valve serves as the fuel fill inlet 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 TUE Current as of 12 14 2010 us ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 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 80 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 v
16. 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 AA Danger Do NOT carry lighted smoking materials or smoke while working on fuel system components Failure to heed 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 ID Current as of 12 14 2010 ROUSH CleanTech F 150 Liquid Propane Injection 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 ins
17. anywhere in the United States To locate the nearest station check with http www afdc energy gov afdc locator stations TED Current as of 12 14 2010 ROUSH CleanTech F 150 Liquid Propane Injection 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 transportation 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
18. connectors and fasteners before applying a wrench to avoid cross threading Failure to heed this caution can result in component damage TUE Current as of 12 14 2010 S ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 1 Attach the fill valve to the fuel filler neck mounting bracket Install the nut and tighten to the specified torque Figure 84 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 85 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 5 Connect the battery EE Current as of 12 14 2010 s ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Installing Fuel Fill Line Filler Neck to Filter 1 Connect the fuel fill line to the filler neck Figure 86 Fuel Fill Line 2 3 4 5 Connect the fuel fill line to the inlet end of the fuel filter and tighten to the specified torque Install new cable ties as needed to secure the fuel fill line If no additional assembly is required open the manual shutoff valve and replace the Multivalve
19. cover 90 degree elbow and pressure relief hose Connect the battery Installing Fuel Fill Line Fuel Filter to Tank 1 2 With fuel tank removed for access thread the fuel fill line fitting to its port on the tank and tighten to the specified torque Install the fuel tank and position the fuel fill line for correct routing SE Current as of 12 14 2010 x ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 3 Connect the fuel fill line securely to the outlet end of the fuel filter and tighten to the specified torque Ec Figure 87 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 5 Connect the battery Installing Fuel Lines Solenoid to Engine 1 Align the forward fuel supply and fuel return lines along the frame rail on the driver s side 2 Attach the forward fuel supply and fuel return lines to the retention clips along the frame rail and to the clips of the bracket on the transmission Push the steel crimp of the fuel return line into the left clip and the rubber sleeve and fuel supply line into the right clip 3 Install the forward fuel return line to the solenoid and tighten to the specified torque Install the forward fuel supply line to the fuel supply line coming from the fuel tank and tighten to the specified torque 5 Push the forward
20. hands clear of the cross brace between the supports as the tank approaches the bed of the truck Failure to heed this warning can result in serious personal injury Figure 72 In Bed Tank on Blocks 11 Detach the hoist and remove the lifting eye 12 Using an Allen key install the protective insert in the weldment 13 Assemble the nuts steel washers and rubber isolators that attach the tank to the truck bed Using a torque wrench tighten the attaching nuts to the specified torque 14 Connect the fuel tank electrical connector Note Ensure that the wire colors are installed in their original locations Figure 73 Electrical Connector 15 Connect the off tank fuel lines to the intermediate fuel lines and tighten to the specified torque EE Current as of 12 14 2010 5 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 16 Attach the off tank fuel lines to the retention clips Figure 74 Fuel Lines 1 Fuel Return Line 2 Fuel Supply Line 17 Connect the fuel fill line to the inlet of the fuel filter and tighten to the specified torque 18 Open the manual shutoff valve 19 Attach the Multivalve cover 20 Attach the 90 degree elbow to the Multivalve cover 21 Attach the pressure relief hose to the 90 degree elbow 22 Attach the pressure relief hose to the outlet nozzle at the fender support rod Constant tension me i clam
21. 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 SE Current as of 12 14 2010 S ROUSH CleanTech F 150 Liquid Propane Injection 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 md m 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 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 80 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 Veh
22. pressure in the fuel rail and lines venting the pressure into a flare stack Figure 44 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 Use 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 SEN Current as of 12 14 2010 a ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Removing Injection Pressure and Temperature Sensor 1 Purge the propane from the fuel lines Figure 45 Injection Pressure and Temperature Sensor 2 Disconnect the electrical connector from the Injection Pressure and Temperature Sensor IPTS 3 Remove the
23. tank is removed from the vehicle All vehicle configurations are similar 1 2 3 Purge the propane from the fuel lines Close the manual shutoff valve on the tank Disconnect the intermediate fuel supply line 1 from the forward fuel supply line and from the off tank fuel supply line Disconnect the intermediate fuel return line 2 from the flow control solenoid and from the off tank fuel return line Remove the fuel lines from the retention clips on the frame rail RUE Current as of 12 14 2010 i ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Super Cab 8 Bed Figure 33 Intermediate Fuel Line Routing Removing Fuel Lines Under Vehicle Toroidal Tank to Solenoid Note The fuel supply and fuel return lines quick connected into the fuel tank Multivalve are serviceable only with the fuel tank removed Purge the propane from the fuel lines Close the manual shutoff valve on the tank Disconnect the tank fuel supply line from the forward fuel supply line Disconnect the tank fuel return line from the flow control solenoid DL qe con NS ues Disengage the fuel lines from the retention clips on the frame rail E Figure 34 Tank Fuel Line Connections Removing Fuel Lines Solenoid to Engine 1 Purge the propane from the fuel lines 2 Close the manual shutoff valve on the tank 3 Disconnect the forward fuel supply line from the tank fuel supply line or
24. EDURES 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 AA 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 is cold The temperature of propane in its liquid sta
25. EPAIR PROCEDURES 335222555522221229222229929240 0222 020255559 vd 2 edd d desi nnmnnn nna 39 Preparing Vehicle for Service eorr eere rore eee nenene aaaea nanne 39 Alen CCCLeD m M 39 Changing TE 40 IN LG Ai xlv E 41 Purging the Fuel Tank acies rtr eria rini rano erc rcna n aa xd anu ai rue a EO EE ERE XE R ER LER EUER KR RA 41 Purging System STEI 41 Manual Fuel Shultoff i 5 4 mre teririrad essa tue ede vonkri ki no SE CoTe CERXFLARR UA Ran EORR EVE DDR Doo o DoD 42 Opening Manual Shutoff Valve eeeeeeeeeeeeeeeeeeeeeeeeeee enne nnn nnne nennt 43 Removing Intake Airbox Cover SetebekskENELESSNSS EEEEREEESEKEEENESENEEEEEENENEKEEERESEEEEEEEENEKEEEN KE 44 Removing Power Steering Fluid Reservoir eeeeeeeeeeeeeeeeeeeeene 45 Installing Power Steering Fluid Reservoir eeeeeeeeeeeneeeeeeeeeeeee 46 RUE Current as of 12 14 2010 i ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Installing Intake Airbox Cover eeeeeeeeeeeeeeeeeeeeeeern nennen Fuel System Component Removal Procedures Removing Pressure Relief Hose eese Removing Flow Control Solenoid eee Removing Fuel Lines In Bed Tank to Solenoid
26. EVEL SENDING UNIT eeeeeeeeeieeeeeeeeeeee eene nanaonan eaan aaaeeeaa namaa nennen 12 Fuel Filler Valve and Fill Line seet 1e eceeerieeu tne nna run ann innu in dran van aot g a Cuna Eu nenna 12 Hm IUE 12 INEEINE FIETER s eese dee dee dee dee deed eege 12 El rrr ap ER 13 HEN Current as of 12 14 2010 i ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement COMPONENT LOCA EA 15 Engine Compartment EE 15 Fuel Rails and RTE 15 GhaSSIS escccrccccscetorcecceseecccsscccessaeeceeeewenasssscsssssescceeedc eee sseeussceucedeeceeeeseeerasnoooeetes 16 Fuel Lines and TanKS ossi ix xin oco c ECC n RR n Rn d RR Paw 16 TROUBLESHOOT ING e 17 Symptom T ables REPE 17 Fuel OG LI 17 Diagnostic Flow Charts EE 18 NG FI Conditio N z ER 18 Slow Teen Oe RE 24 No Start Condition rr conn nee roin eec in sd ed e X d 26 Fuel Pump DIAGNOSTICS ER 27 Fuel Sending Unit NI Ee WEE 33 F el Fill Table cay auarus rci La v dia ed xcu Pad kn vnd d cx ed Fa Rd e de LER VERRE Kee ETE EUER 36 MAINTENANCE REQUIREMENT ecce e reeseeeee nennen nena nana anna 37 Oo hed e 37 Maintenance Procedures ssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn 37 Intake Air Filter INSPO euim RR 37 In Line Fuel Filter Replacement seiscciiecieec sets cecsevsacaseasacecesseadaeanuacannssuacsranaenvanssanndonmons 38 R
27. F 150 Liquid Propane Injection 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 12 VOLTS NOT PRESENT ACROSS PIN E AND PIN F OR MUCH LESS THAN AND POLARITY IS BATTERY VOLTAGE CORRECT Go to Step 4 Go to Step 3 EE Current as of 12 14 2010 d ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 3 CHECK FOR 12 VOLT POWER AT THE 4 PIN CONNECTOR S Pm Win 8 e b ap b e SD o m j o j Tun y DU 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 BATTERY VOLTAGE CO
28. OFF SHUTOFF CONTROL SOLENOID VALVE VALVE SUPPLY LINE N N EN EN PRESSURE RELIEF HOSE PRESSURE RELIEF SOLENOID VALVE Z Lei CUTOFF FC1 FILL RECEPTACLE K FILTER X 12 14 2010 Cu rrent as of 12 71 4 201 0 90 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Electrical Wiring Diagram Wiring Schematic KZ OM 0z 90 TFA Nid IJOYNd dea 1 OMY 02 48 01 z 05 8 Nid ORIGINAL FP RELAY KICK PANEL RED 16 AWG FUSE BLOCK KICK PANEL PK BK 16 AWG BNIWT 16 AWG FUEL SUPPLY SHUTOFF z al t OG 16 AWG RED BK 12 AWG omy 91 ama Ma BLACK 16ANG PROPANE FUSE PANEL ENGINE BAY COWL CONNECTOR 12 14 2010 Cu rrent as of 12 1 4 201 0 CROSSMEMBER GROUND 2008 FORD F 150 PROPANE 5 4 91 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Vehicle Harness SE Current as of 12 14 2010 s ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement In Tank Wire Harness AHOLIMS 34nSS3Hd 39vo8L31IHWMOTI3A 6 A GIONS 10S Alddns 39vo39ia3iHNWNMOSNHS 8 A GION310S Aldd NS J39Y9 9L MOVIGMNId 4 A HOSN3S 08 39v9 9 aNg yyya 9 PHA dd Wd 13n3 39Y9 ZL MOVISDNId S AdMndT1and 39vozi3iiHWNMOSS v AuOSNas 08 3dovogr xovig FOV SLALINM MOTISA z A YSONSS mAa3113nd 39
29. OUSH CleanTech necessary Warranty at 1 800 59 ROUSH necessary SE Current as of 12 14 2010 Si ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 5 CHECK FOR SHORT CIRCUIT IN 12 VOLT SUPPLY TO FUSE BOX Procedure 1 Verify ROUSH wire harness isn t damaged 2 Pin out to make sure short isn t in the harness HARNESS OK Unplug F Series Flow Control Solenoid FCS or E Series Fuel Rail Pressure Control Module FRPCM Does short go away with FCS or FRPCM unplugged Replace solenoid or pressure control module Locate and repair short in harness HARNESS DAMAGED Repair harness and retest Unplug 6 pin fuel tank connector Is there a short in circuit from fuse box with connector unplugged NO FAILURE IN TANK Call ROUSH CleanTech Warranty at 1 800 59 ROUSH TUE Current as of 12 14 2010 S ROUSH CleanTech F 150 Liquid Propane Injection 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 all wire crimps are made properly and that there are no loose connections DAMAGED LOOSE O
30. R CONNECTOR AND HARNESSES IMPROPERLY PINNED WIRES OK 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 IUD Current as of 12 14 2010 E ROUSH CleanTech F 150 Liquid Propane Injection 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 switch will not close and will prevent the tank from filling NO RESTRICTIONS OR PLUGGED FILTER
31. ROUSH CLEANTECH 2007 5 2008 Ford F 150 LIQUID PROPANE INJECTION Rev 12 14 2010 SERVICE MANUAL SUPPLEMENT ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement FOREWORD This manual is a supplement to the Ford F 150 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 F 150 Liquid Propane Injection vehicles Service procedures for vehicle components shared in common with Ford F 150 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 ERUIT Current as of 12 14 2010 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement TABLE OF CONTENTS ROTTIA n dD MO E A i LIMITED LIABILITY DISCLAIMER nnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nne i INTRODUCTION WE 1 General InformalloD z oae m tamcn DII IDCM LE 1 ROUSH CleanTech Techn
32. RRECT Repair open circuit in ROUSH Refer to the Ford Workshop CleanTech harness from 4 pin Manual to determine fault connector to 6 pin connector SEN Current as of 12 14 2010 ae ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 4 CHECK RESISTANCE ACROSS TERMINALS OF FUEL SENDING UNIT Figure 18 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 Tank Configuration Full 3 4 1 2 1 4 Empty F 150 In Bed Toroidal 147 123 84 48 16 Im Current as of 12 14 2010 SS ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement MAINTENANCE REQUIREMENTS Schedule With the exception of the fuel system follow the Ford Maintenance Schedules and Workshop Manual for all F 150 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 Filter Inspection Figure 19 In
33. UL d i NE EEN OBD CAD Fuel LPG Completed Vehicle Maximums GVWR 6007 max CurbW 6949 max Frontai Area 60 0 ft2 max No adjustments needed TWC HO2S SFI HAFS 5 4L Group BRIITO5 45HK L Evap BRIIFO265LPG EE Figure 1 ROUSH CleanTech VECI Label Typical Ford Motor Company VEHICLE EMISSION CONTROL INFORMATION Conforms to regulations 2008 MY FFV U S EPA IT2B8 LDT4 OBD En California 5 4L Group 8FMXTO5 44HF Evap 8FMXRO250NBR Figure 2 Ford VECI Label Typical SE Current as of 12 14 2010 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement VECI Label Location The ROUSH CleanTech VECI label appears along with the original Ford VECI label in the following location e F 150 under hood at front driver side Figure 3 VECI Label Location 12 14 2010 Cu rrent as of 12 71 4 201 0 5 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement DESCRIPTION AND OPERATION System Overview The ROUSH CleanTech Liquid Propane Injection LPI 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 Figure 4 LPI Fuel System Typical Propane is stored in the vehicl
34. Y9 81 J NYYO JOYIA L LINDYID NOILLdldHOS3d ON JAIM Current as of 12 14 2010 SS 12 14 2010 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement TOOLS AND EQUIPMENT Special Tools Fuel Pressure Gauge Kit 0 500 psi f Safety Glasses SE Current as of 12 14 2010 i ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Eyebolt and 5 8 11 Locknut RES Gloves Approved for Propane Leak Detector Liquid Leak Detector EE Current as of 12 14 2010 m
35. ath The valve is intended to shut off fuel flow from the tank in case the supply line comes 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 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 TED Current as of 12 14 2010 B ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 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 filter Bed removed from picture for clarity Route Fill line over frame rail as shown prior to final positioning of tank Figure 11 Fuel Filler Neck
36. cle until low on fuel below 8096 tank capacity and attempt refill RUE Current as of 12 14 2010 m ROUSH CleanTech F 150 Liquid Propane Injection 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 lt 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 direct sunlight or vehicle has been run for an extended period of time Cool tank down or try to fill at a time o
37. e the fuel as is needed 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 4 Disconnect the negative battery cable from the battery RUE Current as of 12 14 2010 d ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Manual Fuel Shutoff Note This procedure ensures that no propane leaves the fuel tank during service activity AA 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 Remove the spring clamp and pressure relief hose from the 90 degree elbow on the Multivalve cover Figure 23 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 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 800 597 6874 4 With the co
38. e 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 two 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 ROUSH CleanTech LPI vehicles require HD 5 propane rated for automotive use Use 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 a separate component in F 150 applications and is located on the frame side rail in the fuel return line In order to safely store pressurized liquid propane
39. ed this caution can result in component damage ID Current as of 12 14 2010 SY ROUSH CleanTech F 150 Liquid Propane Injection 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 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 800 597 6874 Removing Intake Airbox Cover 1 Purge the propane from the fuel lines 2 Remove the three hose clamps from the intake air tubing Figure 25 Hose Clamps 1 2 and 3 Intake Air Tubing 3 Remove the intake airbox cover ID Current as of 12 14 2010 is ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Note Protect the filter element when setting the cover aside Figure 26 Intake Airbox Cover with Filter Element 1 Removing Power Steering Fluid Reservoir 1 Purge the propane from the fuel lines 2 Prepare to catch escaping fluid Figure 27 Power Steering Fluid Reservoir 3
40. ehicle 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 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 F Series vehicles the solenoid is a separate unit mounted on the frame rail in the return fuel line 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 resi
41. el tank 11 Position the fuel tank under the vehicle 12 Tuck the fuel lines fuel fill line and wiring harness up against the fuel tank Slowly raise the fuel tank into position Make sure to align the mounting holes of the tank with the mounting bracket holes 13 Raise the fuel tank into position Make sure to align the mounting holes of the tank with the mounting bracket holes 14 Loosely install the tank mounting bolts into the frame brackets and the spare tire brackets Do not tighten until all tank mounting fasteners are aligned and installed 15 With all fuel tank mounting fasteners installed tighten all mounting fasteners to the specified torque 16 Remove the hoist and lifting straps 17 Install the safety cables and fasteners and tighten to specified torque EE Current as of 12 14 2010 ee ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 18 Position the safety tub under the fuel tank install the fasteners and tighten to the specified torque Figure 64 Fuel Tank Safety Tub and Cables 19 Connect the fuel tank 6 pin connector to the main body harness connector Install tie straps as necessary to secure the harness Figure 65 Fuel Tank Electrical Connector SEN Current as of 12 14 2010 E ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 20 Connect the fuel supply line to the forward fuel supply line and the fuel return line to the fuel control s
42. enseeeeeeeeeeeeeeesseesenesseeneees 86 SO CII le E 87 EA GING SP CCUG QUO INS E 87 ROUSH CleanTech Conversion Ford 5 4L LPI Engine 87 Chassis Specifications icici eceeeeeeecreeerreeeels 87 Fastener Torque Valueg eeeeeeeeeeeeeeeeeeeeeeeeeeeeeEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEeEE 88 SCHEMATICS e 90 Fuel System Flow Diagrams s nssesssnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn 90 gi Co An 90 Electrical Wiring Diagram NEEN 91 WING Schematic 25 ecccoadeiiper sais eniuc Die dde LUGD a0 C QUE a CV CIS RR ESI SUV E DUE AT E REN SG a a R LNE EE iadan UOS 91 Vehicle Harness m 92 In Tank Wire FAMN SS e 93 TOOLS AND EQUIPMENT ccccccseeeeeeseceesssseeseeeeeesseeeceeeeasssseeeeeesseeeoooeanass 94 Special TOS si ee 94 ER Current as of 12 14 2010 d ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement INTRODUCTION General Information This manual applies to the following ROUSH CleanTech Liquid Propane Injection applications e 2007 5 2008 F 150 5 4L 3V This manual is a supplement to the regular Ford Workshop Manual covering the unique components of the ROUSH CleanTech Liquid Propane Injection system e Fuel supply line e Fuel return line e Flow Control Solenoid FCS e Fuel rails e Fuel filler lines valve and filter e Fuel tank The ROUSH CleanTech parts generally se
43. eparate the valve from the bracket 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 Figure 40 Fuel Filter Assembly 2 Disconnect the fuel fill line at the fuel filter outlet fitting 3 Loosen the fuel filter clamp 4 Remove the fuel filter Removing Fuel Fill Line Neck to Filter AA 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 TE Current as of 12 14 2010 E 2 3 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Disconnect the fuel fill line from the filler neck Remove the fuel fill line Removing Left Driver s Side Fuel Rail
44. er Cross 4 Lower Cross Brace Brace L Bracket 2 FuelLine Shield 2 required 3 Lower Cross Brace 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 at the Multivalve quick connect supply port 18 Disconnect the fuel return line at the Multivalve quick connect return port 19 Remove the fuel fill line 20 Remove the E clip and pull off the fuel supply solenoid Removing Under Vehicle Toroidal Tank Note Provide a suitable place to put the fuel tank so that it can be worked on after removing the tank from the vehicle The tank may 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 ID Current as of 12 14 2010 e ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 3 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 Cut any tie straps as necessary Figure 51 Spring Clamp and Pres
45. f 12 14 2010 S ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 9 CHECK MANUAL VALVE OPERATION Procedure 1 Visually check the valve setting 2 Is 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 WELL ABOVE 14 Solenoid open 12 14 OHMS NEAR 0 OHMS Solenoid shorted Using Scan Tool check for Diagnostic Trouble Replace solenoid and Codes DTC s retest OTHER DTC s NO DTC s Refer to FRPCM Repair according to Ford Call ROUSH CleanTech Diagnosis in this service Workshop Manual and Warranty at 1 800 59 ROUSH guide retest ID Current as of 12 14 2010 E ROUSH CleanTech F 150 Liquid Propane Injection 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 16 6 Pin Harness Connector Vehicle Side TUE Current as of 12 14 2010 ES ROUSH CleanTech
46. f 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 ID Current as of 12 14 2010 n ROUSH CleanTech F 150 Liquid Propane Injection 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 to fuse box Go to Step 5 SUPPLY CIRCUIT SUPPLY CIRCUIT OK OPEN Check for open circuit both positive and Refer to schematic and repair circuit as ground in wire harness from fuse box to fuel tank 6 pin connector OPEN NOT OPEN Repair circuit as Call R
47. f valve and replace the Multivalve cover 90 degree elbow and pressure relief hose 5 Connect the battery Fuel System Component Removal Procedures Removing Pressure Relief Hose 1 Disconnect the pressure relief hose from the outlet nozzle bracket at the fender support Constant tension clamp here Figure 31 Pressure Relief Hose Lower Connection EE Current as of 12 14 2010 i 2 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Disconnect the pressure relief hose from the 90 degree elbow in the Multivalve cover Removing Flow Control Solenoid 1 Purge the propane from the fuel lines Figure 32 Flow Control Solenoid and Fuel Lines 1 Retention Clip 3 Intermediate 2 Intermediate Return Line Supply Line 4 Flow Control Solenoid 2 Disconnect the forward fuel return line at the solenoid 3 Disconnect the intermediate fuel return line at the solenoid 4 Disconnect the solenoid electrical connector 5 Remove the solenoid from its mounting bracket Removing Fuel Lines In Bed Tank to Solenoid Note The fuel supply and fuel return lines between the solenoid and the tank are each in multiple sections The off tank sections attached to the Multivalve by quick connect fittings and pass through the tank grommet to terminate below the truck bed Except for the pressure relief hose the Multivalve and fuel lines are inaccessible until the
48. fuel supply and fuel return lines into the quick connect fittings on the respective fuel rails Installing Fuel Lines Under Vehicle Tank to Solenoid Note The fuel supply and fuel return lines quick connected into the fuel tank Multivalve are serviceable only with the fuel tank removed 1 Align the tank fuel supply line with the forward fuel supply line attach the fittings and tighten to the specified torque 2 Align the tank fuel return line with the flow control solenoid thread in the fitting and tighten to the specified torque EE Current as of 12 14 2010 li ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 3 Press the tank fuel lines with sleeves into the retention clips on the frame rail Figure 88 Tank Fuel Line Connections Installing Fuel Lines In Bed Tank to Solenoid 1 Attach the lines to the retention clips on the frame rail 2 Connect the intermediate fuel supply line to the forward supply line route lines behind the flow control solenoid Tighten the fittings to the specified torque 3 Connect the intermediate fuel return line to the rear fitting on the flow control solenoid and tighten to the specified torque Installing Flow Control Solenoid 1 Assemble the solenoid onto the mounting bracket 2 Using a torque wrench tighten the attaching bolts to the torque specified 3 Connect the intermediate and forward fuel return lines to the solenoid
49. he 90 degree elbow and brass tube to the Multivalve use anti seize on the threads prior to assembly 12 14 2010 Current as of 12 14 2010 71 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 26 Install the pressure relief hose to the 90 degreee elbow and attach the spring clamp Figure 69 Spring Clamp and Pressure Relief Hose 27 Install the negative battery cable 28 Refer to the LPG 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 800 597 6874 29 With Snoop or similar product leak check the injectors fuel rails and lines Repair as necessary 30 Start and run the engine and check for diagnostic trouble codes Repair as necessary Any questions please contact ROUSH CleanTech Customer Service at 800 597 6874 Installing In Bed Tank Note Before installing the in bed tank into the vehicle provide a place for prepping the tank for installation Because the tank collar around the Multivalve restricts access connections to the Multivalve must be made before installing the tank in the truck bed 1 Obtain a 5 8 11 threaded lifting eye and a hoist capable of safely lifting 1000 pounds 2 Using an Allen key remove the protective insert from the tapped weldment on top of the tank Install the lifting eye into the we
50. he 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 RUE Current as of 12 14 2010 i ROUSH CleanTech F 150 Liquid Propane Injection 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 to crank or run Compare fuel rail pressure with fuel tank pressure Fuel rail pressure should be at least
51. help from an assistant 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 16 Detach the hoist and remove the lifting straps 17 Remove the convolute tubing from the fuel lines 18 Remove the convolute tubing from the fuel fill line and the electrical cables 19 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 PSI Design Pressure Label here aem Sut Fuel Return Line EE TT DA Fuel Supply Line T f bod XA Figure 59 Multivalve Connections 20 Pull the fuel lines out of the tank collar 21 Remove the E clip and pull off the fuel supply solenoid TED Current as of 12 14 2010 ER ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 22 Remove the fuel fill line from the fitting on the Multivalve N Figure 60 Fuel Fill Line 23 Pull the fuel fill line through the tank collar Fuel Tank Installation Procedures LPG System Bleed and Fill Procedure The following procedure is required in order to ensure that the fuel system i
52. ical Assistance ccccceeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeneeeeeeeeeeeeneees 1 le HIN 1 Fill E m c da Easa 1 Range and Fuel EcOnOImyi aacra iav pua eee EH DX XE ER ELE ULM VE EUER VO EY xard E 2 LAN ld Lt Le me 2 Alert E TE 2 Installation Garaging and Training ceeeeeeeeeeeeeeeeenee 3 Purging and Venting Tanks and Lines nee 3 VEHICLE INFORMATION eeeee enun nennen enun nnn n nne n ananas asas sana nnne nnmnnn 4 B lld gor ic gems o 4 Vehicle Emissions Control Information VECI Labels 4 VECI Label e EE E E 5 DESCRIPTION AND OPERATION ecce eeeeeeeee nennen nena anna nna anna annnn 6 cuBeU rI me 6 Vehicle a ln e EE 7 System Components and Function eese 8 Fuel Rails and Injectors is e nonc nonno n OO RT TD RD TT T D T 8 Flow Control Solenoid FCS sis iisceieiseiseeve nest aeu pau saeua edd edd NR NER AX RR RRRaE 8 Injection Pressure and Temperature Sensor IPTS eess 9 Fuel Supply and Return Lines ius desistit borea E Robo ablic adn end EE ck bx ird NOE ROS VEVE UAR 9 dig al P 10 Multival Ve Pc 11 FUEL L
53. icle Starting The ROUSH CleanTech LPI 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 RUE Current as of 12 14 2010 d ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement System Components and Function Fuel Rails and Injectors The Ford OEM fuel rails and injectors are replaced with ROUSH CleanTech LPI fuel rail and injector assemblies including injection pressure and temperature sensor IPTS Schrader port for service and crossover fuel line Figure 5 Fuel Rails and Injectors Flow Control Solenoid FCS On F Series vehicles a Flow Control Solenoid FCS is used to control fuel flow through the fuel rails The FCS is installed in the fuel return line and mounted on the left frame side rail in the under cab area Figure 6 Flow Control Solenoid RUE Current as of 12 14 2010 S ROUSH CleanTech F
54. intermediate fuel supply line in bed tank equipped RUE Current as of 12 14 2010 i ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 4 Disconnect the forward fuel return line from the fuel control solenoid Figure 35 Forward Fuel Return Line at Flow Control Solenoid 5 Release the forward fuel supply line from the rear of the right side fuel rail quick connect fitting 6 Release the forward fuel return line from the rear of the left side fuel rail quick connect fitting 7 Remove the forward fuel lines from the retention clips on the frame rail and from the brackets on the transmission Transmission Bracket Le TENG TaN ZA SEES ESSA d i K e f Leg SA EE EL NOLL E a Ke ANI Y gt A SN MA Aw V zi Figure 36 Forward Fuel Line Connections Removing Fuel Fill Line Filter to Tank Note The fuel fill line cannot be disconnected from the Multivalve until 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 severe personal injury or property damage EE Current as of 12 14 2010 Si ROUSH C
55. ldment Connect the off tank fuel supply line to the quick connect fitting on the Multivalve RUE Current as of 12 14 2010 ge ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 5 Connect the off tank fuel return line to the quick connect fitting on the Multivalve Figure 70 Fuel Lines and Electrical Connector 6 Assemble the fuel fill line on the Multivalve and tighten the connector to the specified torque 7 Assemble the convolute tubing on the fuel fill line and the electrical cables Assemble the convolute tubing on the off tank fuel lines EE Current as of 12 14 2010 Ke ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 9 Assemble the shield onto the fuel tank and tighten the shield fasteners to the torque specified Figure 71 In Bed Fuel Tank Shield Components 1 Upper Cross 4 Lower Cross Brace Brace L Bracket 2 FuelLine Shield 2 required 3 Lower Cross Brace 10 With the help of an assistant attach the hoist and position the tank onto the truck bed A Caution The off tank fuel lines attached to the Multivalve 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 EE Current as of 12 14 2010 e ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement AA Warning Keep
56. leanTech F 150 Liquid Propane Injection Service Manual Supplement 1 Close the manual shutoff valve on the tank 2 Disconnect the fuel fill line at the fuel filter 3 Arrange the line so that it can pass easily through the truck bed if removing an in bed fuel tank or can pass over the frame rail on under vehicle Toroidal fuel tank 4 Remove the fuel tank to gain access to the fuel fill line on the tank Multivalve 5 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 38 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 PRU Current as of 12 14 2010 2 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Figure 39 Fill Valve and Fuel Filler Neck Mounting Bracket 5 Remove the fill valve to mounting bracket nut and s
57. lve Sizes 31 6 mm 27 65 mm Equipment Air Conditioning Standard Heavy Duty Payload Package Optional Not available with Super Crew Cab Tires and Wheels Variable with option package Trailer Tow Package Required Chassis Specifications Wheelbase Model Cab Body Type 5 5 Box 6 5 Box 8 0 Box F 150 Regular Cab 126 145 Super Cab 133 145 163 Super Crew Cab 139 150 NOTE Vehicle dimensions are as quoted in the Ford Owner s Guide except that options are available only as shown in the following table 12 14 2010 Current as of 12 14 201 0 87 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Fastener Torque Values Fasteners Torque in N m Lb Ft Lb In In Bed Under Vehicle Description Cylindrical Tank Toroidal Tank Air Box Support Bracket Bolts 25 13 18 2 25 13 18 2 Air Box Tube Clamps 4 10 5 35 4 Ib in 4 0 5 35 4 Ib in Filler Neck Bolts 6 1 53 9 Ib in 6 1 53 9 Ib in Filler Neck Support Rod Bolts 9 1 80 9 Ib in 9 1 80 9 Ib in Flow Control Heat Shield Bolts 10 2 89 9 Ib in 10 2 89 9 Ib in Flow Control Solenoid Bracket Bolts 25 3 18 2 25 3 18 2 Flow Control Solenoid Clamp 10 2 89 9 Ib in 10 2 89 9 Ib in Fuel Rail Mounting Bolts 10 1 89 9 Ib in 10 1 89 9 Ib in
58. lve 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 relieve 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 RUE Current as of 12 14 2010 e ROUSH CleanTech F 150 Liquid Propane Injection Service Manual S
59. ly line from the forward fuel supply line and the fuel tank fuel return line from the fuel control solenoid UN uz LN Lr Figure 54 Fuel Tank Fuel Supply and Fuel Return Line Connections 8 Detach the tank fuel lines from the retaining clips 9 Cut the tie straps and then disconnect the fuel tank 6 pin connector a D su Figure 55 Fuel Tank Electrical Connector RUE Current as of 12 14 2010 SS ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 10 Support the fuel tank safety tub and remove the bolts securing the tube brackets to the tank brackets 11 Remove the safety cable fasteners and cables Figure 56 Fuel Tank Safety Tub and Cables 12 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 13 Remove the two front hanger bolts upper in the isolator bracket attached to the spare tire frame and one lower bolt attached to the fuel tank Figure 57 Fuel Tank Front Mounting Fasteners SEN Current as of 12 14 2010 x ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 14 Remove the bolts attaching the tank mounts to the frame rail brackets and the spare tire carrier bracket at the rear Remove the mounting isolators and crush limiters as necessary Figure 58 Fuel Tank Side Mounting Fastener 15 With the
60. olenoid Tighten the fuel line fittings to the specified torque Figure 66 Fuel Line Connections at Forward Fuel Line and Fuel Control Solenoid 21 Attach the fuel lines to the retaining clips along the frame 22 Route the fuel fill line toward the outlet of the fuel filter 23 Connect the fuel tank to filter fuel fill line to the outlet of the fuel filter Tighten the fitting to the specified torque y Figure 67 Fuel Fill Line at Filter Outlet 24 Turn the manual shutoff valve counterclockwise until it stops This opens the fuel supply to the system TED Current as of 12 14 2010 m Note The manual shutoff valve can be hard to turn From fully open to fully closed is approximately 2 1 2 turns ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Figure 68 Multivalve Assembly 1 Electrical Pass 5 Fuel Filler Inlet Through not Elbow serviceable 6 Fuel Supply Line 2 Manual Shutoff 7 Pressure Relief Valve Valve 3 Fuel Pump Solenoid 4 Fuel Return Line 25 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 t
61. p here Figure 75 Pressure Relief Hose Lower Connection 23 Connect the battery EE Current as of 12 14 2010 9 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 24 Refer to the LPG 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 800 597 6874 25 With Snoop or similar product leak check the injectors fuel rails and lines Repair as necessary 26 Start and run the engine and check for diagnostic trouble codes Repair as necessary Any questions please contact ROUSH CleanTech Customer Service at 800 597 6874 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 If the fuel tank is installed ensure that the manual shutoff valve on the Multivalve is closed iS A PA ey Sa MANUAL Sy SHUTOFF SS Wed VALVE Figure 76 Manual Shutoff Valve EE Current as of 12 14 2010 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Installing Injection Pressure and Temperature Sensor 1 Install the Injection Pressure and Temperat
62. rd Supply Line to Intermediate Supply Line except Super Cab 8 0 Cargo Bed 21 2 15 1 21 2 15 1 Forward Supply Line to Intermediate Supply Line Super 25 5 18 4 25 5 18 4 Cab 8 0 Cargo Bed Fuel Filler Hose to Filler Neck 45 4 33 3 45 4 33 3 Fuel Filler Hose to Fuel Filter 45 4 33 3 45 4 33 8 Fuel Rails to Fuel Lines 21 2 15 1 21 2 15 1 Injection Pressure and Temperature Sensor IPTS 7 1 62 9 Ib in 7 1 62 9 lb in Intermediate Return Line to Flow Control Solenoid blue tag 21 2 15 1 21 2 15 1 Rear Return Line to Intermediate Return Line blue tags 21 2 15 1 21 2 15 1 Rear Return Line to Tank Jumper Return Line blue tags 21 2 15 1 21 2 15 1 Rear Supply Line to Intermediate Supply Line 21 2 15 1 21 2 15 1 Rear Supply Line to Tank Jumper Supply Line 21 2 15 1 21 2 15 1 Service Port Schrader Valve on Fuel Rail 7 1 62 9 lb in 7 1 62 9 lb in 12 14 2010 Current as of 12 14 2010 89 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement SCHEMATICS Fuel System Flow Diagrams Fuel Flow FLEX LINE E FUEL RAIL TEMP FUEL RAIL PRESS RETURN LINE FLEX LINE ORIFICE FOR RETURN o A FLOW CONTROL FUEL FLOW WHEN VALVE SOLENOID VALVE IS CLOSED FUEL TANK Md RETURN CHECK 7 N BACK VALVE FUEL EXCESS SUPPLY MANUAL SUPPLY SHUT
63. res 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 SE Current as of 12 14 2010 E ROUSH CleanTech F 150 Liquid Propane Injection 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 RESTRICTIONS AND OR NO RESTRICTIONS OR PLUGGED FILTER PLUGGED FILTER Repair as required and retest Go to Step 3 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 near 0 amps the fuel fill circuit is not activated and tank will not fill AMMETER READS 0 7 0
64. ressure Relief Hose Lower Connection 6 Disconnect the fuel tank electrical connector Figure 48 Electrical Lines and Connector 7 Remove the nuts steel washers and rubber isolators attaching the tank 8 Obtain a 5 8 11 threaded lifting eye and a hoist capable of safely lifting 1000 pounds 9 Using an Allen wrench remove the protective insert from the tapped weldment on top of the tank 10 Install the lifting eye in the weldment EE Current as of 12 14 2010 i ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 11 With the help of an assistant attach the hoist remove the tank from the truck bed and place it on a suitable surface Figure 49 In Bed Tank on Blocks Note Make a note of the holes in the truck bed through which the fuel and electrical lines pass in order to direct the lines during installation A Caution Fuel lines remain attached to the Multivalve and 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 12 Detach the hoist and remove the lifting eye 13 Install the protective insert in the weldment RUE Current as of 12 14 2010 i ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 14 Remove the shield from the tank Figure 50 In Bed Fuel Tank Shield Components 1 Upp
65. rve 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 800 59 ROUSH with any questions regarding ROUSH CleanTech Liquid Propane Injection systems Start Sequence The ROUSH CleanTech Liquid Propane Injection system is fully integrated 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
66. s 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 Bleed tank from the bleeder valve to ensure no air is present in the system Close the bleeder valve 2 Fill the tank with 0 1 1 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 3 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 5 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 8 Verify that there are no concerns and fill the vehicle and record the total amount of gallons to fill the vehicle EE Current as of 12 14 2010 ii ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Installing Under Vehicle Toroidal 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
67. stor 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 vehicles 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 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 Injector 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 HEN Current as of 12 14 2010 e ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 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 Va
68. sure 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 800 597 6874 ID Current as of 12 14 2010 E ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 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 Note The manual shutoff valve can be hard to turn From fully open to fully closed is approximately 2 1 2 turns EX ak fo y y it CH es NS V Wj Ka V Gi A Figure 52 Multivalve Assembly 1 Electrical Pass 5 Fuel Filler Inlet Through not Elbow serviceable 6 Fuel Supply Line 2 Manual Shutoff 7 Pressure Relief Valve Valve 3 Fuel Pump Solenoid 4 Fuel Return Line 6 Disconnect the fuel tank to filter fuel fill line at the outlet of the fuel filter We D Figure 53 Fuel Fill Line at Filter Outlet 12 14 2010 Cu rrent as of 12 1 4 201 0 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 7 Disconnect the fuel tank fuel supp
69. take Air Duct and Filter Housing Typical This intake air filter assembly is unique to the F 150 and is necessary for the ROUSH CleanTech LPI system The ROUSH CleanTech intake air filter assembly replaces the original Ford assembly SEN Current as of 12 14 2010 d ROUSH CleanTech F 150 Liquid Propane Injection 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 2 Purge residual fuel from the fuel fill line Disconnect the fuel fill line from the fuel filter inlet Figure 20 In Line Fuel Filter Typical 3 4 5 6 Disconnect the fuel fill line from the fuel filter outlet Loosen the clamp retaining the fuel filter in place Remove and discard the filter Place a new fuel filter in position on the filter bracket and tighten the retaining clamp to 4 5 Nem 35 44 Ib in Connect the fuel file lines to the filter inlet and outlet Tighten the line fittings to 41 49 Nem 30 36 Ib ft RUE Current as of 12 14 2010 ao ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement REPAIR PROC
70. tallation 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 ID Current as of 12 14 2010 S ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement VEHICLE INFORMATION Build Data 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 201 1 MY iNCOMPLETE LPG Weight limits refer to Emission Certification only DO NOT EXCEED VEHICLE GVWR See Incomplete Vehicie Manual U S EPA T2B Mi OBD CAI ANUT Al CG California S
71. te 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 ID Current as of 12 14 2010 Se ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Changing Fuses Figure 21 Fuse Panel The fuse panel is located on the bulkhead under the hood on the driver s side Figure 22 20 Amp and 15 Amp Fuses Always use a fuse of the correct amperage when replacing fuses RUE Current as of 12 14 2010 a ROUSH CleanTech F 150 Liquid Propane Injection 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 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 pressure relief hose clamps to an elbow that attaches the cover to the Multivalve The press
72. 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 and open circuit HARNESS OK NOT OK Call ROUSH CleanTech Repair harness and Warranty at retest 1 800 59 ROUSH SE Current as of 12 14 2010 S ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 6 CHECK 20 AMP FUSE Figure 15 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 EE Current as of 12 14 2010 ic ROUSH CleanTech F 150 Liquid Propane Injection 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 line Workshop Manual and wiring diagrams RUE Current as o
73. ual Supplement 1 Install and tighten the right side fuel rail bolts to the specified torque Figure 78 Right Side Fuel Rail 2 Connect the crossover fuel line to the right side fuel rail and tighten to the specified torque KE UNAM ZU YD ba Wes Go bau j S Figure 79 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 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 EE Current as of 12 14 2010 e ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement 3 Install and tighten the fuel rail bolts to the specified torque
74. upplement COMPONENT LOCATOR Engine Compartment Fuel Rails and Injectors Figure 12 Fuel Rails and Injectors ID Current as of 12 14 2010 e ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Chassis Fuel Lines and Tanks Crossover Same All Trucks Joints Forward Lines Same All Trucks dy ne o Lines Lines Wheelbase Front Of SE Same All Dependent Vehicle Trucks Rear Lines Bed Length Dependent Figure 13 F 150 Fuel Lines and Tank TUE Current as of 12 14 2010 ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement TROUBLESHOOTING Symptom Tables Fuel Odor Content to be developed ID Current as of 12 14 2010 ud ROUSH CleanTech F 150 Liquid Propane Injection Service Manual Supplement Diagnostic Flow Charts No Fill Condition 1 VERIFY VEHICLE BATTERY IS FULLY CHARGED AND CONNECTED Go to Step 2 a Check battery connections and charge repair as required b 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 solenoid will not open to accept more fuel IS FUEL LEVEL IN TANK BELOW 80 FULL Go to Step 3 Drive vehi
75. ure Sensor IPTS into the left side fuel rail Figure 77 Injection Pressure and Temperature Sensor 2 Connect 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 Torque 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 AA 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 TUE Current as of 12 14 2010 p ROUSH CleanTech F 150 Liquid Propane Injection Service Man
76. ure relief hose elbow and Multivalve cover are removable while the tank is in the vehicle The bleeder valve in the tank wall vents immediately to the atmosphere This valve can also be serviced using a standard box end wrench while the tank is in the vehicle 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 releasing 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 purge the fuel tank and recaptur
77. ver 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 RUE Current as of 12 14 2010 is ROUSH CleanTech F 150 Liquid Propane Injection 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 24 Multivalve Assembly 1 Electrical Pass 5 Fuel Filler Inlet Through not Elbow serviceable 6 Fuel Supply Line 2 Manual Shutoff 7 Pressure Relief Valve Valve 3 Fuel Pump Solenoid 4 Fuel Return 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 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 he

2007.5 - 2008 Ford F-150 LIQUID PROPANE

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