Fulltext TSBs

Technical Service Bulletins

TSB
03-10-4
  • DRIVEABILITY – BI-FUEL LPG LOW FLOW INJECTOR SERVICE ASSEMBLY WITH COOLANT LOCK-OFF
Publication Date: May 13, 2003

FORD:
1998-1999 E SERIES, F-150, F-250

Article 02-10-6 is being republished in its entirety to update the model coverage.

ISSUE:

Some 1998-1999 Bi-Fuel LPG vehicles (With Coolant Lock off) may exhibit a no start condition. This may be caused by stuck Low Flow Injectors on the Compuvalve possibly due to fuel contamination. To avoid the replacement of the Compuvalve when only the Low Flow Injectors have failed, the Low Flow Injectors have been released separately for service.

ACTION:

If diagnosis leads to failed Low Flow Injectors, refer to the following removal and installation procedure to replace the Low Flow Injector assembly.

SERVICE PROCEDURE

WARNING:WHEN SERVICING FUEL RELATED COMPONENTS, ELIMINATE ALL SOURCES OF IGNITION (E.G. TORCHES, HEATERS, AND LIGHTED TOBACCO). FLAMMABLE MIXTURES MAY BE PRESENT AND CAN IGNITE, RESULTING IN DAMAGE AND/OR INJURIES. THE FUEL SYSTEM LINE PRESSURE MUST BE RELIEVED BEFORE ANY COMPONENT CAN BE REMOVED. REMOVAL OF COMPONENTS WITHOUT PRESSURE RELIEF CAN CAUSE AN UNCONTROLLED RELEASE OF PROPANE AND MAY RESULT IN DAMAGE AND/OR INJURIES.

PRELIMINARY PREPARATION

  1. Relieve system line pressure and remove the Compuvalve from the vehicle. Refer to Service Manual GFIP163 for the 1998 LPG Bi-Fuel model year. For 1999 model year Bi-Fuel LPG vehicles refer to the Ford Truck Workshop Information Section 303-04E.

    NOTE:ONCE THE SYSTEM IS DISCONNECTED, COVER ALL OPEN HOSE FITTINGS AND ELECTRICAL CONNECTIONS TO AVOID CONTAMINATION.

  2. Ensure that all loose debris is removed from the injector area, to avoid contamination during removal.
  3. Place the Compuvalve flat on a work bench (with injectors facing up).

    NOTE:ENSURE THAT THE BENCH SURFACES ARE CLEAN AND DIRT FREE. BENCHES SHOULD BE COVERED TO AVOID SCRATCHING COMPONENT SURFACES.

REMOVAL OF LOW FLOW INJECTOR ASSEMBLY

NOTE:DURING THE REMOVAL OF THE LOW FLOW INJECTORS, CARE SHOULD BE TAKEN TO PREVENT ANY DEBRIS FROM ENTERING THE FUEL FLOW OPENINGS.

  1. Carefully cut cable tie (1) securing the Low Flow Injector Assembly (A) harness and discard cable tie (Figure 1).
  2. Remove nut (2) and solenoid casing (3) and set aside (Figure 1).
  3. Remove Coolant Lock-off Solenoid (4) from core tube (5) (Figure 1).

    NOTE:LEAVE THE RUBBER SPACER (6) IN PLACE ON CORE TUBE (5) AFTER REMOVING COOLANT LOCK-OFF SOLENOID (4) (FIGURE 1).

  4. Remove the two mounting screws (7) securing the Injector Fuel Rail (8) to the Compuvalve (9) and discard screws (Figure 1).
  5. Remove the Low Flow Injector Assembly (A) and Injector Fuel Rail (8) from Compuvalve (9). Discard Low Flow Injector Assembly (A) and set aside the Injector Fuel Rail (8) (Figure 1).
  6. Remove O-ring (10) from Compuvalve (9) and discard O-ring (Figure 1).

    NOTE:IF THE COMPUVALVE IS LEFT UNINSTALLED FOR AN EXTENDED PERIOD OF TIME, USE A CLEAN LINT-FREE CLOTH TO COVER ALL EXPOSED OPENINGS TO AVOID CONTAMINATION.

INSTALLATION OF LOW FLOW INJECTOR ASSEMBLY

Assembly Preparation

  1. Ensure all mating surfaces between Compuvalve (9), Injector Fuel Rail (8) and Low Flow Injectors (11) & (12) are clean (Figure 1).

    NOTE:TO CLEAN, GENTLY WIPE SURFACES USING A CLEAN LINT-FREE CLOTH.

  2. Ensure there is lubricant on the inlet and outlet O-rings of the new Low Flow Injectors (11) & (12) and to O-ring (11) (Figure 1).

    NOTE:IF REQUIRED, APPLY A THIN FILM OF NON-SILICON BASED LUBRICANT (E.G. PARKER O-LUBE).

  3. Before installing the Low Flow Injector assembly (A), ensure that the orientation of injector #1 (11) (with shorter wire) and of injector #2 (12) (with longer wire) are positioned as shown (Figure 1).

Assembly Installation

NOTE:DURING THE INSTALLATION OF THE LOW FLOW INJECTORS, CARE SHOULD BE TAKEN TO PREVENT ANY DEBRIS FROM ENTERING THE FUEL FLOW OPENINGS.

  1. Press the outlet of the Low Flow Injectors (11) & (12) into Compuvalve (9) (Figure 1).
  2. Route wires under the outlet portion of the Low Flow Injectors (11) & (12) so that the wires will not become pinched between Compuvalve (9) and the Injector Fuel Rail (8) (Figure 1).
  3. Install O-ring (10) into Compuvalve (9) as shown (Figure 1).
  4. Insert Coolant Lock-off Solenoid (4) onto core tube (5) (orient solenoid as shown) (Figure 1).
  5. Press Injector Fuel Rail (8) onto the inlet of Low Flow Injectors (11) & (12) (Figure 1).
  6. Apply Loctite 272 to the threads of mounting screws (7) (Figure 1).
  7. Line up the two holes in the Injector Fuel Rail (8) with the mounting holes in the Compuvalve (9) and install with mounting screws (7). Torque to 2-2.5 N-m (18-22 Lb-in) (Figure 1).

    CAUTION:ENSURE THAT INJECTOR WIRES ARE NOT PINCHED UNDER THE INJECTORS OR THE INJECTOR FUEL RAIL.

  8. Place solenoid casing (3) over Coolant Lock-off Solenoid (4) and tighten down with nut (2). Torque nut to 5-6 N-m (45-55 Lb-in).
  9. Insert cable tie (1) through the cable tie holder (13) and tighten (Figure 1).
  10. When complete, install Compuvalve (9) to the vehicle and leak test all removed components and fittings. Refer to Service Manual GFIP163 for the 1998 LPG Bi-Fuel model year. For the 1999 LPG Bi-Fuel model year refer to the Ford Truck Workshop Manual Section 310-00C.

PART NUMBERPART NAME
XL3Z-9H529-AAKit – Low Flow Injector

OTHER APPLICABLE ARTICLES:

02-10-4,  03-10-3

SUPERSEDES:

02-10-6

WARRANTY STATUS:

Information Only

OASIS CODES:

206000, 601300, 602300, 603300, 607000, 607400, 608000, 609000, 609400, 611000, 611500




Figure 1 – Article 03-10-4


NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle.

Copyright © 2003 Ford Motor Company