Ford Falcon. Manual - part 178

303-04b-22 

Fuel Charging and Controls — Turbocharger 

303-04b-22

REMOVAL AND INSTALLATION (Continued)

Installation
1.  Installation is the reversal of the removal

procedure.

2.  Check all connections to ensure there are no

airleaks.

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303-04c-1 Single 

Fuel 

LPG 303-04c-1

SECTION : 303-04c Single Fuel LPG

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS  

PAGE

SPECIFICATIONS

 Specifications  .......................................................................................................................303-04c-3

DESCRIPTION AND OPERATION

  Single Fuel LPG  ...................................................................................................................303-04c-4

 Introduction 

 

.........................................................................................................................303-04c-4

  Licensing Requirements   ....................................................................................................303-04c-5

  Important Safety Notice   .....................................................................................................303-04c-5

  Notes, Cautions and Warnings  ..........................................................................................303-04c-6

 Vehicle 

Identification 

 

..........................................................................................................303-04c-7

 Description 

 

.........................................................................................................................303-04c-8

  LPG System Major Components  ......................................................................................303-04c-11

 Converter 

 

..........................................................................................................................303-04c-13

  Engine Servicing Requirements  .......................................................................................303-04c-16

 Scheduled 

Maintenance 

 

...................................................................................................303-04c-17

DIAGNOSIS AND TESTING

  Single Fuel LPG  .................................................................................................................303-04c-20

  Inspection and Verification  ...............................................................................................303-04c-20

 Symptom 

Charts 

...............................................................................................................303-04c-23

  Connector Circuit Reference  ............................................................................................303-04c-26

REMOVAL AND INSTALLATION

 Primary Service  ..................................................................................................................303-04c-29

 LPG Filter  ...........................................................................................................................303-04c-29

 Tank Assembly  ...................................................................................................................303-04c-29

 Pressure Decanting  ............................................................................................................303-04c-29

 Tank Decanting  ..................................................................................................................303-04c-30

  Tank — Ute  ........................................................................................................................303-04c-30

  Tank — Wagon  ..................................................................................................................303-04c-32

  Tank — Sedan  ...................................................................................................................303-04c-33

  Fuel Gauge and Float Assembly  ........................................................................................303-04c-34

  Automatic Fill Limiter  ..........................................................................................................303-04c-34

  Service Valve (With Relief Valve on Ute and Wagon)  .......................................................303-04c-35

  Fuel Filler Valve  .................................................................................................................303-04c-35

  Pressure Relief Valve  .........................................................................................................303-04c-36

  Fuel Filler Hose  ..................................................................................................................303-04c-36

  LPG Fuel Delivery System Hose  .......................................................................................303-04c-36

  Bundy Tube Connection  .....................................................................................................303-04c-37

  Converter Including Filter Lockoff & Solenoid  ....................................................................303-04c-38

 Filter  ...................................................................................................................................303-04c-39

  Main/Idle/Prime Lockoff Solenoids  .....................................................................................303-04c-39

 Converter Assembly  ...........................................................................................................303-04c-39

303-04c-2 Single 

Fuel 

LPG 303-04c-2

(Continued)

 Throttle Body  ......................................................................................................................303-04c-40

DISASSEMBLY AND ASSEMBLY

  Converter with integral Filter/Lock Off 

″ Solenoid  ..............................................................303-04c-41

 Converter  ............................................................................................................................303-04c-41

 Idle Jet  ................................................................................................................................303-04c-45

303-04c-3 Single 

Fuel 

LPG 303-04c-3

SPECIFICATIONS

General Specifications

Description

Nm

Description

Specification

Second stage section bolts (76)

4-5

Fuel Tank

Manufactured by APA

Second stage spring cap (51)

12-15

Industries

First stage lever screws (24)

1.5-2.5

Capacity

First stage cover screw (68)

1.5-2.5

Ute

92 Litres usable

Idle section bolts (76)

4-5

Sedan

93 Litres usable

Support plate screw (5)

2-2.5

Wagon

116 Litres usable

M5 cover nuts (1)

4-6

Fuel sender

40 - 250 ohms. Normal

Inlet lockoff assembly (stem) (15)

16-17

Working Range

Screw stepper motor (not shown)

4-5

Pressure relief valves

Relief Pressure - 2.55

Filter lockoff assembly (15)

22-24

on tanks

MPa

Filter bowl screws (65)

4-6

Pressure relief valve

Relief Pressure - 3.10

Idle plug (17)

3-6

(hydrostatic) on service MPa

line-

Sludge drain plugs (79)

5-7

Service line

Bundy-tube - Preformed

Balance plug (19)

10-15

5/16 " and 3/8 " diameter

with Flexible pressure

hose to the fill line.

Converter assembly

VIALLE - F5 Type

(Special)

Idle Jet

0.8mm diameter

Throttle body and mixer LPG Fuel (38mm I.D.)

assembly
Spark plugs - Iridium

K 20 SR 11

Long Life

Gap 1.1 

± - 0.05mm

Torque Specifications

Description

Nm

Flared connections - All

35-38

Converted bracket to spring tower

17-23

Filler valve plate to bracket fuel tank

8-12

neck
Primary/Lock Off to Converter

10-12

Idle solenoid to converter

10-12

Converter to mounting bracket

4-8

Tank to chassis mounting bolts

80

Service valve to tank

5

AFL to tank 5Nm LPG Gauge (AXIOM) 5

to tank
Converter outlet retainer

4-8

Electrical connector bracket on

4-8 plus

converter lock offs

Loctite 262

Inlet union to converter Filter bowl

15-20

Fuel Tank Neck to Body

21-29

Converter Torque settings

Refer to

Section

310-00.

Nut (73)

1.5-2.5

Bolt water pipes (not shown)

4-5

Second stage lever screws (37)

1.5-2.5

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