Fulltext TSBs

Technical Service Bulletins

TSB
03-4-2
  • FUEL – BI-FUEL – CNG FUEL LEAK AT FILL VALVE – E-SERIES AND F-SERIES CNG FILL VALVE – REVISED SERVICE PARTS
Publication Date: February 18, 2003

FORD:
1997-1999 F-250 LD
1997-2003 E SERIES, F-150

ISSUE:

On some dedicated CNG vehicles, a possible fuel leak may occur at the fuel fill valve. The previous practice to service failed CNG fill valves was with a flange assembly consisting of a flange and a fill valve. That practice needlessly complicated production and service part numbering since the same fill valve in different flange assemblies was numbered differently. The bypass feature for CNG fill valves is no longer required due to revisions in service procedures and equipment. The fill valve for Bi-Fuel vehicles was already serviced separately, but the service part will no longer have a bypass.

ACTION:

The previous flange assembly service parts for dedicated CNG vehicles will be separated into a fill valve and a flange. One fill valve with one part number will be used to service many vehicles. Different flanges will be released to service each vehicle. Most repairs will be for the fill valve only and the existing flange can remain installed in the vehicle. Fill valve service parts for Bi-Fuel F-150/250 and E-250/350 will no longer have the bypass feature. Use Pressure Relief – Use Fuel Line Evacuation procedure for 2002 F-150 or E-Series.

SERVICE PROCEDURE

NOTE:THIS SERVICE PROCEDURE SHOULD ONLY BE PERFORMED BY AN AUTHORIZED CNG FUEL SYSTEM TECHNICIAN.

NOTE:FOLLOW ALL CNG FUEL SYSTEM SAFETY PROCEDURES LISTED IN THE APPROPRIATE WORKSHOP MANUAL.

Fill Valve Removal:

  1. Perform the Fuel Line Evacuation procedure (Refer to the appropriate model year Workshop Manual – Fuel Section).

    NOTE:NEW BI-FUEL FILL VALVES WILL NO LONGER HAVE BYPASS FEATURE. REFER TO 2002 F-150 OR E-SERIES FUEL LINE EVACUATION PROCEDURE SECTION 310-00B. USE BYPASS FITTING ADAPTOR 13400255.

  2. Remove and discard any hard plastic dust cap attached to the body.

    NOTE:A NEW DUST CAP IS PROVIDED WITH THE FILL VALVE SERVICE PART AND IS ALSO AVAILABLE SEPARATELY IF NEEDED.

  3. Using a backup wrench, remove the fuel line tube nut fitting from the fuel filler valve.
  4. Remove the fuel filler valve retaining nut and discard.
  5. Remove the fuel filler valve from the mounting flange:
    1. Disconnect the fuel line from the fuel filler valve.
    2. Remove the fuel filler valve from the mounting flange.

Fill Valve Installation

NOTE:REPLACE THE FUEL LINE O-RING AND LUBRICATE O-RING SEAL WITH 5W-30 ENGINE OIL. WHEN TIGHTENING THE FUEL LINES TO THE FILLER VALVE, A TORQUE WRENCH ADAPTOR MUST BE USED. REFER TO WORKSHOP MANUAL SECTION 310-00B.

  1. Remove dust caps, tether loop, and flange retaining nut from new fill valve.

    NOTE:FOR E-SERIES BI-FUEL CNG APPLICATIONS, FOLLOW INSTRUCTIONS PROVIDED WITH KIT TO INSTALL THE 45 DEGREE FITTING TO THE FILL VALVE FIRST. WHEN INSTALLING THE FILL VALVE IN THE VEHICLE, ORIENTATE THE FILL VALVE SO THE 45 DEGREE FITTING ANGLES AWAY FROM THE PINCH WELD IN THE VEHICLE BODY (FIGURE 1).

  2. Install fuel fill valve in mounting flange:
    1. A) Install and torque retaining nut to 25-27 Lb-ft. (33-37 N-m).

      NOTE:USE A 1 1/4 IN (32 MM) DEEP-WALL SOCKET ON RETAINING NUT.

  3. Place tether loop of dust cap on fill valve inlet and press down to the groove above the retaining nut (Figure 2). Place dust cap on inlet.
  4. Install the fuel line to the fuel filler valve and torque fitting nut to 28-42 Lb-ft. (38-57 N-m).
  5. Check for leaks at the fuel line fitting.

Flange Removal:

Remove fill valve (see previous procedure).

  1. Remove three (3) screws holding flange.
  2. Remove flange from vehicle.

Flange Installation:

  1. Hold flange behind fuel fill bucket so three (3) screw holes in flange align with three slots.
  2. Install three (3) screws and torque to 25-30 Lb-in. (2.7-3.3 N-m).

    E/F SERIES PARTS LIST
    VehicleOld Flange AssemblyNew Separate PartsDescription
    1997-1999 F-150/250 Dedicated CNG – 3000 psiXL3Z-9034-ACF7UZ-9C112-AAFill Valve
    F75Z-9039-EAFlange
    2000-2003 F-150/250 Dedicated CNG – 3600 psiYL3Z-9034-AA2C2Z-9C112-AAFill Valve
    F75Z-9039-EAFlange
    1998-1999 F-150/250 Bi-Fuel CNG – 3600 psiXL3Z-9D278-AAGF2C2Z-9C112-AAFill Valve
    2000-2002 F-150/250 Bi-Fuel CNG – 3600 psiYL3Z-9D278-BA2C2Z-9C112-AAFill Valve
    1997-1999 E-250/350 Dedicated CNG – 3000 psiXC2Z-9034-ABF7UZ-9C112-AAFill Valve
    F7UZ-9039-BAFlange
    2000-2003 E-250/350, 2001-2003 E-450 Cutaway Dedicated CNG – 3600 psiYC2Z-9034-AC2C2Z-9C112-AAFill Valve
    F7UZ-9039-BAFlange
    1998-1999 E-250/350, Bi-Fuel – 3600 psiXC2Z-9D278-AAGFF8UZ-9C132-AAFill Valve Kit
    All E/F Series2C2Z-9030-AAInlet Dust Cap



PART NUMBERPART NAME
F7UZ-9C112-AAFill Valve
F75Z-9039-EAFill Valve Flange
F7UZ-9039-BAFill Valve Flange
2C2Z-9C112-AAFill Valve
F8UZ-9C132-AAFill Valve Kit
2C2Z-9030-AAInlet Dust Cap

OTHER APPLICABLE ARTICLES:

NONE

WARRANTY STATUS:

Information Only

OASIS CODES:

404000, 490000




Figure 1 – Article 03-4-2




Figure 2 – Article 03-4-2


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