Fuel System (CNG) - Fill Valve Leaks
Article No.03-11-7
06/09/03
DRIVEABILITY - CNG - POSSIBLE FUEL LEAK AT
FILL VALVE - FILL VALVE SERVICE PART
REVISIONS - CNG VEHICLES ONLY
FORD:
1996-2003 CROWN VICTORIA
Article 03-4-9 is being republished in its entirety to update the Service Part numbers due to a Supplier change.
ISSUE
On some CNG (Compressed Natural Gas) Crown Victoria vehicles, a possible fuel leak may occur at the fuel fill valve. When replacing the fill valve, the previous practice for these vehicles was to service failed CNG till valves with a flange assembly consisting of a flange, a fill valve, a rubber boot, and a dust cap. That practice needlessly complicated production and service part numbering across different vehicle lines 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. A new fill valve supplier has been approved for Crown Victoria.
ACTION
The previous service part (flange assembly) will be separated into a fill valve, a flange, and a rubber boot. One fill valve with one Part Number will then 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 and boot can remain installed in the vehicle. A replacement dust cap is provided with each fill valve service part and is also available separately.
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 venting portion of the Fuel System Pressure Release procedure in Workshop Manual Section 310-00B. (For older vehicles equipped with a manual back flow valve, refer to appropriate Model Year Workshop Manual).
2. Remove rubber boot and four (4) retaining screws behind flange and set aside.
3. Using a backup wrench, remove the fuel line tube nut fitting from the fuel filler valve.
4. Remove the flange retaining nut and discard.
NOTE
USE A 1-3/8 IN DEEP-WALL SOCKET ON RETAINING NUT.
5. Remove the fuel filler valve from the mounting flange.
Fill Valve Installation:
NOTE
LUBRICATE 0-RING SEAL ON FILL VALVE 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.
NOTE
FUEL TEST LEAK PROCEDURE (REFER TO SECTION 310-00B IN WORK SHOP MANUAL)
1. Remove dust caps and flange retaining nut from new fill valve.
2. Install fuel fill valve in mounting flange
3. Install and torque flange retaining nut to 24-30 N.m (18-22 lb-ft).
NOTE
USE A 1-1/4 IN OR 32 MM DEEP-WALL SOCKET ON RETAINING NUT.
Parts List
4. Install rubber boot over back end of till valve behind flange with bulge facing forward.
5. Install and torque four (4) retaining screws to 2.8-4.0 N.m (25-35 lb-in).
6. Install the fuel line to the fuel filler valve and torque fitting nut to 38-57 N.m (28-42 lb-ft) using a backup wrench.
7. Check for leaks at the fuel line fitting (refer to Workshop Manual).
Flange Removal:
Remove fill valve (see previous procedure).
1. Remove four (4) bolts holding flange.
2. Retain fill valve dust cap.
Flange Installation:
1. Hold flange in fuel fill bucket so four (4) screw holes align with four (4) holes in bucket with sharp end of central depression pointing to the rear.
2. Install four (4) bolts and torque to 2.7-3.3 N.m (25-30 lb-in) with grommet of dust cap under lower front bolt.
NOTE
USE A 1-3/8 IN DEEP-WALL SOCKET ON BRASS RETAINING NUT. USE 1-1/4 IN OR 32 MM DEEP-WALL SOCKET ON STEEL RETAINING NUT.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 03-4-9
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 404000, 490000
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