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CNG - Possible Fuel Leak At Fill Valve (03-4-9)

Publication date: 2003-06-09
Reference number: 03-4-9
Supersedes refnos: 03-11-7

CNG - POSSIBLE FUEL LEAK AT FILL VALVE

CNG - POSSIBLE FUEL LEAK AT FILL VALVE

TECHNICAL SERVICE BULLETIN

Reference Number(s): 03-11-7, Date of Issue:  June 9, 2003
FORD: 1996-2003 CROWN VICTORIA
Superceded Bulletin(s): 03-4-9, Date of Issue:  March 3, 2003

DESCRIPTION

DRIVEABILITY - CNG - POSSIBLE FUEL LEAK AT FILL VALVE - FILL VALVE SERVICE PART REVISIONS - CNG VEHICLES ONLY

NOTE: 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 fill 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 O-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 ft-lb).
    NOTE: USE A 1 1/4 IN OR 32 MM DEEP-WALL SOCKET ON RETAINING NUT.
  4. Install rubber boot over back end of fill valve behind flange with bulge facing forward.
  5. Install and torque four (4) retaining screws to 2.8-4.0 N.m (25-35 in-lb).
  6. Install the fuel line to the fuel filler valve and torque fitting nut to 38-57 N.m (28-42 ft-lb) 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 in-lb) 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 INFORMATION

CROWN VICTORIA PARTS LIST

Vehicle Old Flange Assembly New Separate Parts Description
1996-2001 Crown Victoria Dedicated CNG - 3000 psi XW7Z-9A244-AA F7UZ-9C112-AA Fill Valve
2002-2003 Crown Victoria Dedicated CNG - 3600 psi 2W7Z-9A244-AA 2C2Z-9C112-AA Fill Valve
All Model Years --- F6AZ-9039-AC Flange
All Model Years --- F6AZ-9008-AA Boot
All Model Years --- 2C2Z-9030-AA Dust Cap
PARTS INFORMATION

Part Number Part Name
F7UZ-9C112-AA Fill Valve
2C2Z-9C112-AA Fill Valve
F6AZ-9039-AC Flange
F6AZ-9008-AA Boot
2C2Z-9030-AA Dust Cap

WARRANTY INFORMATION

WARRANTY STATUS: Information Only.

OASIS CODES: 404000, 490000

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