Test HC: Fuel Delivery System

This pinpoint test is intended to diagnose:
- Chassis components
- Engine vacuum
- Fuel pressure
- Fuel filter
- Fuel supply
- Fuel injector

SYSTEM INSPECTION
1. Visually inspect the components of the fuel delivery system.

VISUAL INSPECTION CHART

Mechanical
- Loose, leaking, or damaged fuel or vacuum lines
- Leaking fuel injectors
- Adverse driveability symptoms, such as rough idle, hard to start, misses, surges, hesitates, backfires
- Insufficient fuel in fuel tank

Electrical
- Discharged battery
- Damaged connectors
- Damaged insulation
- Damaged components in the fuel system
- Blown fuse
- Tripped inertia fuel shutoff switch

2. Exercise the wiring and connectors for the solenoids and other electrical components for obvious problems due to looseness, corrosion, or other damage.
3. If a component is suspected as the obvious cause of a fault, correct the cause before proceeding to the next step.

HC1 - HC4:

4. If all system inspection checks are OK, proceed to the Pinpoint Test HC1.

FUEL SYSTEM DEPRESSURIZATION PROCEDURE

Pressure Relief - Liquid Propane Gas Bi-Fuel System

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 SHUTOFF 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 -42C (-44F), 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 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.

Pressure Relief - Natural Gas Bi-Fuel System

WARNING:
- DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS. DO NOT INSTALL COMPONENTS NOT SPECIFICALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIFICALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION FOR THE 5.4L F-SERIES 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.
- IT IS IMPORTANT THAT YOUR BI-FUEL VEHICLE BE CORRECTLY MAINTAINED BY FORD BI-FUEL TRAINED PERSONNEL. IF A CONCERN OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF A CONCERN RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. BI-FUEL COMPONENTS AND GASOLINE SPECIFIC COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH BI-FUEL SERVICE PROCEDURES, DAMAGE CAN OCCUR AND YOUR WARRANTY MAY BE INVALIDATED.
- FUEL SUPPLY LINES ARE ALWAYS PRESSURIZED. WHEN SERVICING 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 NATURAL GAS FUEL SYSTEM IS ALWAYS PRESSURIZED TO 655 KPA (95 PSI) DOWNSTREAM OF THE FUEL PRESSURE REGULATOR AND UP TO 24,821 KPA (3,600 PSI) UPSTREAM OF THE FUEL PRESSURE REGULATOR. USE CARE WHEN SERVICING THE FUEL SYSTEM OR PERSONAL INJURY CAN OCCUR.
- THE NATURAL GAS FUEL SUPPLY MANIFOLD IS PRESSURIZED TO 655 KPA (95 PSI). FUEL PRESSURE MUST BE RELIEVED PRIOR TO ANY FUEL SYSTEM SERVICE.

Instructions
To Release The Pressure From The System:
1. Turn the supply valve clockwise to the fully closed position. (There will still be residual pressure present.)
2. Set the fuel selector switch to the ALT position.
3. Start the engine and run the vehicle until the indicator lamp goes out.

CAUTION: Use care to prevent combustion from fuel spillage. No smoking, open flames, or any kind of arcing.

SAFE FUEL HANDLING PRACTICES - GASOLINE, CNG, AND LPG

FIRE
- REPORT ALL FIRES to the appropriate authorities.
- Know the locations of portable fire extinguishers, fire blankets, fire alarms, and eyewash shower facilities. Learn how to use them.
- Use a B or AFFF (light water) type FIRE EXTINGUISHER to fight flammable liquid fires.

FIRST AID
- IF SWALLOWED:
- If GASOLINE has been swallowed, DO NOT induce vomiting. SEEK MEDICAL ATTENTION IMMEDIATELY!
- When someone is overcome by vapors, if safe, MOVE VICTIM TO FRESH AIR. If not breathing, give artificial respiration or CPR (cardiopulmonary resuscitation) as appropriate. SEEK MEDICAL ATTENTION IMMEDIATELY!
- If splashed in eyes, FLUSH with large amounts of water for 15 minutes. Remove contact lenses, if worn. SEEK MEDICAL ATTENTION.
- If splashed on skin, remove contaminated clothing. WASH SKIN thoroughly with soap and water.

HEALTH
- ALL FUELS may be HARMFUL OR FATAL IF SWALLOWED.
- BE AWARE: if swallowed, onset of serious health effects may be delayed 12 to 24 hours.
- ALL FUEL VAPORS may be harmful by inhalation.
- ALL FUELS may be harmful by skin absorption.
- ALL FUELS are irritating to the eyes and respiratory system.
- FUELS made with gasoline may contain benzene, which is a cancer-causing agent.

HANDLING
- USE FLAMMABLE LIQUID HANDLING PRECAUTIONS.
- DO NOT SMOKE or use heat/spark producing equipment near vapors.
- DO NOT eat, smoke, or drink where fuel products are handled, processed, or stored.
- Wear chemical goggles and nitrile gloves (additional protective clothing and equipment may be necessary in some instances).
- NEVER SIPHON BY MOUTH.
- Use in well-ventilated areas, and control vapors. Be aware that gasoline, CNG, and LPG vapors are NOT visible. Gasoline and LPG vapors are heavier than air, can travel along the floor, and will settle in lower areas.
- Keep flammable fuels in approved, labeled, closed containers.
- When transferring or venting flammable fuels, BOND the receiving container to the source and GROUND the source to the earth.
- WASH HANDS thoroughly after handling any fuel.