Fuel System Leak Test

Liquid Propane Gas

WARNING:
^ AVOID INHALING 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, 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 REPAIR AND DO NOT OPEN THE 80% STOP-FILL VALVE WHILE A VEHICLE IS INSIDE A BUILDING. WHEN REPAIRING 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 REPAIRED, HAVE THE FUEL EVACUATED BY TRAINED PERSONNEL AT A LOCAL PROPANE FUEL STATION. LIQUID PROPANE 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 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.
^ IT MAY BE NECESSARY TO USE A PAINT DRYING OVEN TO CURE AUTOMOTIVE FINISHES WHEN A VEHICLE BODY REQUIRES REPAINTING OR AFTER INSTALLING A SECOND UNIT BODY ONTO THE FORD CHASSIS. IF THE VEHICLE IS CURED IN AN OVEN, THE TEMPERATURE MUST NOT EXCEED 60°C (140°F). THE DRYING TIME IN THE OVEN MUST NOT EXCEED 40 MINUTES. THE FUEL MUST BE EVACUATED FROM THE LINES PRIOR TO CURING THE VEHICLE IN THE PAINT DRYING OVEN.
^ 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 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.

NOTE: In high ambient temperatures, such as those experienced in desert locations, the fuel system is designed to vent excess fuel vapor pressure. The pressure relief valve will vent fuel and automatically reset itself.

1. Observe all warnings when performing the liquid propane gas leak test.

WARNING:
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS OR INSTALL A NEW COMPONENTS WITH COMPONENTS NOT SPECIFICALLY DESIGNED FOR USE WITH THE BI-FUEL VEHICLE. FORD MOTOR COMPANY HAS SPECIFICALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION FOR THE BI-FUEL VEHICLE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT CAN RESULT IN FIRE OR PERSONAL INJURY OR CAUSE ENGINE DAMAGE.
^ FUEL SUPPLY LINES ARE ALWAYS PRESSURIZED. WHEN REPAIRING FUEL RELATED COMPONENTS, DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE. FLAMMABLE MIXTURES MAY BE PRESENT AND CAN IGNITE, RESULTING IN PERSONAL INJURY.
^ 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 GAS TO ESCAPE INTO THE AIR AND CAUSE INJURY OR DEATH.

2. Fill the fuel tank to 1/2 maximum pressure.

NOTE: Do not use the Rotunda Combustible Gas Leak Detector on bi-fuel vehicles.

3. Cycle the ignition to the RUN position twice, then OFF to pressurize the entire fuel system.
4. Beginning with the fill valve and following the system through to the fuel injectors, apply a quantity of mild soapy water to each fitting or component seam. Leaks in the system will exhibit soapy bubbles.
5. Repair any leaks discovered.

WARNING: THE BI-FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO ANY LEAK REPAIR OR PERSONAL INJURY MAY OCCUR.

6. Fuel the tank(s) to full pressure.
7. Repeat the soapy water application and repair any leaks discovered.