ROUSH F-150 Operating manual

2007.5 - 2008
Ford F-150
LIQUID PROPANE INJECTION
Rev. 12/14/2010
SERVICE MANUAL SUPPLEMENT

Current as of 12-14-2010
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.
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Service Manual Supplement
TABLE OF CONTENTS
FOREWORD............................................................................................................i
LIMITED LIABILITY DISCLAIMER.........................................................................i
INTRODUCTION.....................................................................................................1
General Information...........................................................................................1
ROUSH CleanTech Technical Assistance...................................................................... 1
Start Sequence ................................................................................................................. 1
Fill Stations....................................................................................................................... 1
Range and Fuel Economy................................................................................................ 2
Safety Information .............................................................................................2
Alert Messages................................................................................................................. 2
Installation, Garaging and Training.................................................................3
Purging and Venting (Tanks and Lines)..........................................................3
VEHICLE INFORMATION......................................................................................4
Build Data ...........................................................................................................4
Vehicle Emissions Control Information (VECI) Labels.................................................. 4
VECI Label Location......................................................................................................... 5
DESCRIPTION AND OPERATION........................................................................6
System Overview...............................................................................................6
Vehicle Starting ................................................................................................................7
System Components and Function.................................................................8
Fuel Rails and Injectors................................................................................................... 8
Flow Control Solenoid (FCS)........................................................................................... 8
Injection Pressure and Temperature Sensor (IPTS)...................................................... 9
Fuel Supply and Return Lines......................................................................................... 9
Fuel Tanks....................................................................................................................... 10
Multivalve........................................................................................................................ 11
FUEL LEVEL SENDING UNIT.............................................................................................................. 12
Fuel Filler Valve and Fill Line ........................................................................................ 12
FILL VALVE ......................................................................................................................................... 12
IN-LINE FILTER.................................................................................................................................... 12
Glossary............................................................................................................13
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Service Manual Supplement
COMPONENT LOCATOR....................................................................................15
Engine Compartment ......................................................................................15
Fuel Rails and Injectors................................................................................................. 15
Chassis .............................................................................................................16
Fuel Lines and Tanks..................................................................................................... 16
TROUBLESHOOTING .........................................................................................17
Symptom Tables..............................................................................................17
Fuel Odor......................................................................................................................... 17
Diagnostic Flow Charts...................................................................................18
No Fill Condition............................................................................................................. 18
Slow Fill Condition......................................................................................................... 24
No Start Condition.......................................................................................................... 26
Fuel Pump Diagnostics.................................................................................................. 27
Fuel Sending Unit Diagnostics...................................................................................... 33
Fuel Fill Table.................................................................................................................. 36
MAINTENANCE REQUIREMENTS.....................................................................37
Schedule...........................................................................................................37
Maintenance Procedures ................................................................................37
Intake Air Filter Inspection............................................................................................. 37
In-Line Fuel Filter Replacement .................................................................................... 38
REPAIR PROCEDURES......................................................................................39
Preparing Vehicle for Service.........................................................................39
Alert Messages............................................................................................................... 39
Changing Fuses.............................................................................................................. 40
Pressure Relief ............................................................................................................... 41
Purging............................................................................................................................ 41
Purging the Fuel Tank.................................................................................................... 41
Purging System Fuel Lines............................................................................................ 41
Manual Fuel Shutoff ....................................................................................................... 42
Opening Manual Shutoff Valve...................................................................................... 43
Removing Intake Airbox Cover ..................................................................................... 44
Removing Power Steering Fluid Reservoir.................................................................. 45
Installing Power Steering Fluid Reservoir.................................................................... 46
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Service Manual Supplement
Installing Intake Airbox Cover....................................................................................... 46
Fuel System Component Removal Procedures ...........................................47
Removing Pressure Relief Hose ................................................................................... 47
Removing Flow Control Solenoid................................................................................. 48
Removing Fuel Lines (In-Bed Tank to Solenoid)......................................................... 48
Removing Fuel Lines (Under-Vehicle Toroidal Tank to Solenoid)............................. 49
Removing Fuel Lines (Solenoid to Engine).................................................................. 49
Removing Fuel Fill Line (Filter to Tank)........................................................................ 50
Removing Fuel Filler Neck............................................................................................. 51
Removing Fuel Filter Assembly .................................................................................... 52
Removing Fuel Fill Line (Neck to Filter) ....................................................................... 52
Removing Left (Driver’s Side) Fuel Rail........................................................................ 53
Removing Right (Passenger’s Side) Fuel Rail............................................................. 54
Removing Fuel Injector.................................................................................................. 55
Removing Injection Pressure and Temperature Sensor............................................. 56
Fuel Tank Removal Procedures.....................................................................57
Purging Fuel Tank.......................................................................................................... 57
Removing In-Bed Tank................................................................................................... 57
Removing Under-Vehicle Toroidal Tank....................................................................... 60
Fuel Tank Installation Procedures.................................................................66
LPG System Bleed and Fill Procedure ......................................................................... 66
Installing Under-Vehicle Toroidal Tank ........................................................................ 67
Installing In-Bed Tank .................................................................................................... 72
Fuel System Component Installation Procedures .......................................77
Before Installing Components....................................................................................... 77
Installing Injection Pressure and Temperature Sensor............................................... 78
Installing Fuel Injector ................................................................................................... 78
Installing Right (Passenger’s Side) Fuel Rail............................................................... 78
Installing Left (Driver’s Side) Fuel Rail......................................................................... 79
Installing Fuel Filter Assembly...................................................................................... 81
Installing Fuel Filler Neck .............................................................................................. 81
Installing Fuel Fill Line (Filler Neck to Filter) ............................................................... 83
Installing Fuel Fill Line (Fuel Filter to Tank)................................................................. 83
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Service Manual Supplement
Installing Fuel Lines (Solenoid to Engine) ................................................................... 84
Installing Fuel Lines (Under-Vehicle Tank to Solenoid).............................................. 84
Installing Fuel Lines (In-Bed Tank to Solenoid)........................................................... 85
Installing Flow Control Solenoid................................................................................... 85
Installing Pressure Relief Hose..................................................................................... 86
SPECIFICATIONS................................................................................................87
Engine Specifications .....................................................................................87
ROUSH CleanTech Conversion Ford 5.4L LPI Engine ................................................ 87
Chassis Specifications....................................................................................87
Fastener Torque Values..................................................................................88
SCHEMATICS ......................................................................................................90
Fuel System Flow Diagrams...........................................................................90
Fuel Flow......................................................................................................................... 90
Electrical Wiring Diagram...............................................................................91
Wiring Schematic ........................................................................................................... 91
Vehicle Harness.............................................................................................................. 92
In-Tank Wire Harness..................................................................................................... 93
TOOLS AND EQUIPMENT ..................................................................................94
Special Tools....................................................................................................94
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Service Manual Supplement
INTRODUCTION
General Information
This manual applies to the following ROUSH CleanTech Liquid Propane Injection applications:
•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:
•Fuel supply line
•Fuel return line
•Flow Control Solenoid (FCS)
•Fuel rails
•Fuel filler lines, valve and filter
•Fuel tank
The ROUSH CleanTech parts generally serve the same functions as the Ford parts they
replace.
The online Ford Workshop Manual, if available, continues to apply to all other details. The
diagnostic chart in this manual directs the technician to appropriate sections of the Ford
manual for applicable remedies in some situations.
Propane, like other fuels, must be handled safely with knowledge of its characteristics. Training
in propane characteristics and handling is available through the Propane Education and
Research Council (PERC), 1140 Connecticut Avenue, Washington, DC 20036. Their web
address is www.propanecouncil.org.
ROUSH CleanTech Technical Assistance
Call ROUSH CleanTech customer service at 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 anywhere in the United States. To locate the nearest station,
check with http://www.afdc.energy.gov/afdc/locator/stations/.
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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.
Danger: Although propane is nontoxic, nonpoisonous, has the lowest flammability range of
any alternative fuel and dissipates quickly when released into the atmosphere, propane vapor
is heavier than air and seeks the lowest point. When the ratio of propane to air is between
2.2% and 9.6%, propane will burn in the presence of an ignition source at 940°F (504°C) or
hotter. Keep away from heat, sparks, flames, static electricity or other sources of ignition.
Failure to heed this danger may result in severe personal injury or death.
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.
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.
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.
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Service Manual Supplement
Installation, Garaging and Training
Chapter 11 of NFPA 58 applies to engine fuel systems using LP-Gas in internal combustion
engines, including containers, container appurtenances, carburetion equipment, piping, hose
and fittings and their installation. Additionally, this chapter applies to garaging of vehicles and
to the training of personnel.
Paragraph 11.2 specifies that each person engaged in installing, repairing, filling or otherwise
servicing an LP-Gas engine fuel system shall be trained. Contact the Propane Education and
Research Council to learn more about their CETP E-Learning computer-based training
program: [e-mail], or [e-mail].
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.
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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
Figure 1 — ROUSH CleanTech VECI Label (Typical)
Figure 2 — Ford VECI Label (Typical)
S
S
S
A
A
A
M
M
MP
P
PL
L
LE
E
E
S
S
S
A
A
A
M
M
MP
P
PL
L
LE
E
E
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