Fuel Delivery Valve Assembly: Service and Repair

BI-FUEL MODELS ONLY

REMOVAL

WARNING:
^ AVOID INHALING PROPANE GAS OR OCCUPYING CONFINED AREAS CONTAINING PROPANE. PROPANE IS HEAVIER THAN AIR. THE HEAVIER GAS CAN DISPLACE OR PUSH FRESH AIR OUT OF AN AREA. IN LARGE QUANTITIES, PROPANE CAN DISPLACE ENOUGH OXYGEN TO MAKE THE SURROUNDING AIR UNFIT TO BREATHE AND POSSIBLY CAUSE ILLNESS. IF A PERSON BREATHES PROPANE GAS OR AIR THAT LACKS OXYGEN DUE TO THE PRESENCE OF PROPANE GAS, HEADACHE, DIZZINESS, AND WEAKNESS IN THE EXTREMITIES CAN OCCUR. IN SEVERE CASES, PROLONGED BREATHING OF PROPANE-FOULED AIR CAN CAUSE SUFFOCATION. IN THE EVENT OF ILLNESS FROM INHALING PROPANE GAS, MOVE THE VICTIM IMMEDIATELY TO FRESH AIR AND CONTACT A PHYSICIAN OR MEDICAL EMERGENCY PERSONNEL FOR ARTIFICIAL RESPIRATION OR OTHER REQUIRED TREATMENT.
^ DO NOT NEEDLESSLY VENT PROPANE FUEL DURING SERVICE, AND DO NOT OPEN THE 80% STOP-FILL VALVE WHILE A VEHICLE IS INSIDE A BUILDING. WHEN SERVICING THE FUEL SYSTEM, FOLLOW THE RECOMMENDED PROCEDURES TO SHUT OFF THE FUEL TANKS AND RUN THE ENGINE OUT OF FUEL BEFORE DISCONNECTING THE FUEL SYSTEM COMPONENTS. IF THE FUEL TANK(S) ARE BEING SERVICED, HAVE THE FUEL EVACUATED BY TRAINED PERSONNEL AT A LOCAL PROPANE FUEL STATION. LIQUID PROPANE FUEL VAPORIZES AT NORMAL BAROMETRIC PRESSURE AT TEMPERATURES ABOVE -42°C (-44°F), AND EXPANDS TO 270 TIMES ITS VOLUME AS A LIQUID. UNNECESSARY VENTING OF PROPANE FUEL CAN CREATE FIRE AND HEALTH HAZARDS WHICH COULD CAUSE PERSONAL INJURY OR DEATH.
^ BE ALERT FOR SITUATIONS THAT MAY CAUSE THE PROPANE FUEL SYSTEM TO VENT FUEL. THESE INCLUDE EXTREMELY HOT DAYS, PARKING NEAR A SPACE HEATER, OR HOISTING A VEHICLE UP NEAR A CEILING HEATER. RELEASE OF PROPANE FUEL IN A CONFINED AREA THROUGH THE PRESSURE RELIEF VALVE COULD OCCUR. THE RELEASE OF PROPANE FUEL IN A CONFINED AREA COULD RESULT IN AN ACCUMULATION OF FLAMMABLE VAPORS. IF FUEL IS VENTED NEAR A HEAT SOURCE, A FIRE OR EXPLOSION COULD OCCUR.
^ DO NOT USE PAINT DRYING OVENS FOR PROPANE-FUELED VEHICLES. THE HEAT OF PAINT DRYING OVENS WILL INCREASE THE PRESSURE IN THE FUEL TANKS. THIS COULD CAUSE VENTING OF PROPANE FUEL VAPOR INTO THE OVEN AND RESULT IN A FIRE FROM THE HEAT OR SPARKS IN THE ELECTRICAL EQUIPMENT. IF THE FUEL IS CONFINED INSIDE AN OVEN AN EXPLOSION MAY OCCUR. WHEN REFINISHING THE BODY PANELS OF A PROPANE FUELED VEHICLE USE SPOT PAINTING AND DRYING METHODS.
^ IF A CONFINED AREA, SUCH AS A LUBRICATION PIT, HAS BEEN SUBJECTED TO PROPANE GAS THE AREA SHOULD BE INSPECTED FOR ADEQUATE OXYGEN LEVELS BY A LOCAL HEALTH DEPARTMENT BEFORE BEING ENTERED OR PERSONAL INJURY OR DEATH MAY OCCUR.
^ THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY COMPONENT CAN BE REMOVED. THE FUEL TANKS MUST BE EVACUATED PRIOR TO TANK REMOVAL. REMOVAL OF COMPONENTS WITHOUT PRESSURE RELIEF OR TANK EVACUATION CAN CAUSE PROPANE FUEL TO ESCAPE INTO THE AIR AND CAUSE INJURY OR DEATH.

1. Relieve the LPG fuel pressure.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Drain the engine cooling system. For additional information, refer to Cooling System.
4. Remove the air cleaner and outlet tube as an assembly.







5. Remove the accelerator snow shield.







6. Disconnect the fuel outlet line.







7. Disconnect the speed control cable.







8. Remove the bolts and screws.







9. Remove two bolts and disconnect the harness connector.







10. Disconnect the three connectors.







11. Disconnect the vacuum line.







12. Disconnect the fuel line and the coolant lines and remove the compuvalve.

WARNING: USE NEW COPPER WASHERS ONLY; THE REUSE OF COPPER WASHERS MAY CAUSE SEALING ISSUES AND LIQUID PROPANE GAS LEAKS IN THE ENGINE COMPARTMENT.

INSTALLATION







1. Position the compuvalve and connect the fuel line and the coolant lines.

WARNING: USE NEW COPPER WASHERS ONLY; THE REUSE OF COPPER WASHERS MAY CAUSE SEALING ISSUES AND LIQUID PROPANE GAS LEAKS IN THE ENGINE COMPARTMENT.







2. Connect the vacuum line.







3. Connect the three connectors.







4. Connect the harness connector.







5. Install the bolts and screws.







6. Connect the speed control cable.







7. Connect the fuel outlet line.







8. Install the accelerator snow shield.
9. Install the air cleaner and outlet tube as an assembly.
10. Connect the battery ground cable.
11. Pressurize the LPG fuel system.
12. Leak test the LPG fuel system.
13. Fill and bleed the cooling system. For additional information, refer to Cooling System.