31S14T0 ford CNG vehicle 1999 2002

1999-2002 Ford Dedicated CNG Vehicles student guide FCS-13396-REF Course Code 31S14T0 IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following these directions will help assure reliability There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he/she compromises neither his/her personal safety nor the vehicle integrity by his/her choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle Always wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the vehicle Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission, it should be in NEUTRAL (engine OFF) or NEUTRAL (engine ON) WITH THE PARKING BRAKE ON unless instructed otherwise for a specific operation Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide Keep yourself and your clothing away from moving parts, such as the fan and belts, when the engine is running To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Do not smoke while working on the vehicle To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual or the Workshop Manual In any cases where there may be a conflict, the provisions of the Warranty and Policy Manual or the Workshop Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc., recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice Produced and Coordinated by Technical Support Operations, Ford Customer Service Division March, 2002 CONTENTS Contents INTRODUCTION AND PREREQUISITE REVIEW ALTERNATIVE FUEL VEHICLE (AFV) CURRICULUM Ford Dedicated CNG Vehicle Instructor-Led Course Description Course Terminal Objectives Audience Course Prerequisites Evaluation Student Guide SERVICE STANDARDS Prerequisite Review Intro-2 Intro-3 Intro-3 Intro-3 Intro-3 Intro-4 Intro-4 Intro-5 Intro-6 LESSON 1: INTRODUCTION TO DEDICATED CNG VEHICLES DEDICATED CNG VEHICLES - WHAT IS NATURAL GAS? - Alternative Fuel Comparison Table .1 - Identification of Ford Dedicated CNG Vehicles .1 - Changes to Base Vehicle Components on Dedicated CNG Vehicles - Changes to Base Vehicle Operating Strategies - Supplemental Information On Alternative Fuel Vehicles .1 - LESSON 2: DEDICATED CNG OPERATION DEDICATED CNG VEHICLE THEORY OF OPERATION - CNG FUEL SYSTEM PRESSURES - ACTIVITY — WORKSHEET A (Hands-On) - 10 ACTIVITY — WORKSHEET B (Hands-On) - 11 ACTIVITY — WORKSHEET C (Written) - 12 ACTIVITY — WORKSHEET D (Written) - 13 LESSON 3: DEDICATED CNG COMPONENTS INTRODUCTION TO DEDICATED CNG COMPONENTS - CNG Fuel Fill Valve - Fuel Tanks - Solenoid Tank Valve .3 - Fuel Tank Vent Box .3 - Fuel Lines - Quarter-Turn Valve .3 - 10 Fuel Filters - 11 High Pressure Regulator - 12 Fuel Injection Supply Manifold - 14 Fuel Injectors - 16 CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DEVICES - 18 Inputs and Outputs Chart - 19 Powertrain Control Module (PCM) - 20 Unique CNG PCM Input Devices - 21 Unique CNG Outputs of the PCM - 22 Alternative Fuel Control Module (AFCM) - 23 AFCM Outputs - 25 i CONTENTS ACTIVITY — WORKSHEET E (Hands-On) - 28 ACTIVITY — WORKSHEET F (Hands-On) - 29 ACTIVITY — WORKSHEET G (Written) - 30 ACTIVITY — WORKSHEET H (Written) - 31 LESSON 4: DEDICATED CNG VEHICLE DIAGNOSIS AND SERVICE DEDICATED CNG FUEL SYSTEM DIAGNOSTIC PROCEDURES .4 - SYMPTOM-TO-SYSTEM-TO-COMPONENT-TO-CAUSE (SSCC) DIAGNOSTIC STRATEGY - SERVICE AREA PRECAUTIONS - PRELIMINARY DIAGNOSTIC STEPS - IDENTIFICATION AND RETRIEVAL OF CNG SYSTEM DIAGNOSTIC TROUBLE CODES (DTCs) - SERVICE PUBLICATION NAVIGATION .4 - Powertrain Control/Emissions Diagnosis (PC/ED) Manual - Workshop Manual - 11 Wiring Diagrams (EVTMs) - 11 COMPONENT AND SYSTEM TESTING AND SERVICE - 12 Coolant System Pressure Testing - 13 Fueling Dedicated CNG Vehicles - 14 CNG Contamination - 16 Fuel Fill Valve Filter - 17 Coalescent Filter Service - 18 Fuel Injector Cleaning - 19 Fuel Tank Removal .4 - 20 Fuel Line Service - 21 Fuel System Leak Testing - 22 Crown Victoria Vent Box Leak Test .4 - 24 Fuel System Venting - 25 Solenoid Tank Valve Diagnostics - 27 DEMONSTRATION - DEDICATED CNG VEHICLE DIAGNOSTICS .4 - 29 DEMONSTRATION - DEDICATED CNG FUEL VENTING AND SOLENOID DIAGNOSIS - 33 ACTIVITY — WORKSHEET I (Hands-On) - 38 ACTIVITY — WORKSHEET J (Written) - 40 ACTIVITY — WORKSHEET K (Written) - 41 APPENDIX 1: COMPRESSED NATURAL GAS SAFETY APPENDIX 2: AFV NEW GENERATION STAR TESTER OPERATION GLOSSARY ii INTRODUCTION AND PREREQUISITE REVIEW DAY ONE INTRODUCTION AND PREREQUISITE REVIEW CONTENTS OBJECTIVES Introduce the Ford Alternative Fuel Curriculum Administer the prerequisite review Alternative Fuel Vehicle (AFV) Curriculum Ford Dedicated CNG Vehicle Instructor-Led Course Description Course Terminal Objectives Audience Course Prerequisites Evaluation Student Guide Service Standards Prerequisite Review 1999 - 2002 Ford Dedicated CNG Vehicles March, 2002 Intro - INTRODUCTION AND PREREQUISITE REVIEW DAY ONE ALTERNATIVE FUEL VEHICLE (AFV) CURRICULUM ALTERNATIVE FUEL VEHICLE CURRICULUM MAP Alternative Fuel Vehicle New Generation STAR Web-Based Training - Course CodeWB 31S09W0 (Optional for Ford Dealership Technicians, Mandatory for Fleet Technicians,) Alternative Fuel Handling Safety Web-Based Training - Course CodeWB 31S10W0 (Mandatory for all Technicians) Flexible Fuel Vehicle Web-Based Training - Course CodeWB 31S11W0 (Mandatory for Ford Dealership Technicians, Optional for Fleet Technicians) Ford Bi-Fuel CNG/LPG Vehicle (3-Day) Instructor-Led Training - Course Code 31S13T0 (Mandatory for Ford Dealership Technicians, Optional for Fleet Technicians) Ford Bi-Fuel CNG Vehicle (2-Day) Instructor-Led Training - Course Code 31F16T0 (Fleet Technicians Only) Ford Bi-Fuel LPG Vehicle (2-Day) Instructor-Led Training - Course Code 31F17T0 (Fleet Technicians Only) Ford Dedicated CNG Vehicle (2-Day) Instructor-Led Training- Course Code 31S14T0 (Mandatory for Ford Dealership Technicians, Optional for Fleet Technicians) Ford Electric Ranger Instructor-Led Training- Course Code 34N07T0 (Optional for all Technicians) Courses of the Alternative Fuel Vehicle (AFV) Curriculum The Alternative Fuel Vehicle Curriculum consists of six courses related to Alternative Fuel Vehicle (AFV) diagnosis and service With the exception of the Ford Electric Ranger Course, each course in the curriculum is a “building block” for the next course in the curriculum This curriculum is designed for technicians who want to learn the methods and techniques to properly diagnose and service AFV systems and components Curriculum Goals The goals of this curriculum are as follows: Provide the necessary training to enable technicians to “FIX IT RIGHT THE FIRST TIME, ON TIME.” Increase technician productivity with respect to AFV diagnosis and service Increased customer satisfaction Intro - March, 2002 1999 - 2002 Ford Dedicated CNG Vehicles DAY ONE INTRODUCTION AND PREREQUISITE REVIEW Ford Dedicated CNG Vehicle Instructor-Led Course Description This is the second instructor-led course in the Alternative Fuel Vehicle Curriculum It is a two-day course facilitated by an instructor This course is designed to provide hands-on opportunities for technicians to learn and improve their skills with respect to utilizing tools and equipment and to apply knowledge learned in previous curriculum courses Course Terminal Objectives Using the information and activities provided by this course the technician will: accurately diagnose and repair Alternative Fuel Vehicle concerns using the appropriate tools and equipment employ appropriate methods and techniques when servicing Alternative Fuel Vehicle systems and components Audience This course is designed and intended for Ford Motor Company dealership technicians who are enrolled in the STST Alternative Fuel Vehicle Curriculum Additionally, this course is also designed for training service technicians of Ford Designated Fleets Course Prerequisites A technician taking this course should have the following prerequisite skills, knowledge and/or experience: Automotive Electrical 34S14T0 Automotive Electronics 34S19T0 Engine Performance Theory and Operation 31S07T0 Engine Performance Diagnosis and Testing 31S10T0 Additionally, technicians attending this course must have completed the following: Alternative Fuel Vehicle New Generation STAR Web-Based Training (Mandatory for Fleet Technicians, optional for Ford Dealership Technicians) Alternative Fuel Safety Web-Based Training (Mandatory for all Technicians) Flexible Fuel Vehicle Web-Based Training (Mandatory for Ford Dealership Technicians) 1999 - 2002 Ford Dedicated CNG Vehicles March, 2002 Intro - INTRODUCTION AND PREREQUISITE REVIEW DAY ONE Evaluation Hands-on skills and course related knowledge is evaluated on the afternoon of the second day Hands-on evaluations will be conducted with exercises in: – alternative fuel vehicle system diagnosis – alternative fuel vehicle system service – service publication CD-ROM/DVD navigation – special tool usage In order to pass the course, you must demonstrate acceptable skills at the evaluated hands-on exercises AND you must answer at least 80% of the written post test questions correctly Student Guide The Student Guide contains the worksheets used at the workstations for each of the two days You must complete each worksheet IMPORTANT: Actively participate in exercise reviews This is your opportunity to ask questions and clear up any areas that you may not fully understand Intro - March, 2002 1999 - 2002 Ford Dedicated CNG Vehicles NGS APPENDIX Clearing Alternative Fuel Vehicle (AFV) DTCs BF 5-7 NGS Displaying DTCs 12 Any codes present will then be displayed 13 Write down all DTCs displayed Refer to the Specific Code Diagnostics chart in the service manual supplement (1998 MY) or the PC/ED Manual (1999 MY and later) for diagnostic information on any DTCs present 14 DTCs should be cleared whenever directed by a pinpoint test and after performing vehicle service The procedure for clearing codes is to: Retrieve DTCs as previously described Once DTCs have been retrieved, press the CLEAR button (7) If a code reappears, a fault is still present If, after correcting all DTCs or if no DTCs are present, the symptom still exists, refer to the Specific Condition Diagnostics Chart in the service manual supplement (1998) or the DTC chart in the PC/ED manual (1999 and later) Appendix - March, 2002 1999 - 2002 Ford Dedicated CNG Vehicles NGS APPENDIX NGS Parameter Identification Data (PID) Function BF 5-8 Selecting PID Menu There are situations where a sensor or component has deteriorated; yet its signal is not outside the programmed calibrations of the module In these cases, operation of the vehicle may be affected, yet no DTC will be stored in memory For this reason, the NGS has the Parameter Identification Data (PID) mode The PID mode of the NGS allows you to see the signal as interpreted by the module In this way, you can watch the signal and determine if it is responding within specifications, or if its operation is erratic or slow The following procedure allows you to enter the PID menu, select, view and record PIDs: To enter the PID menu, first, enter the AFCM menu in the DIAGNOSTIC DATA LINK menu, as you did to retrieve codes Then, enter the PID DATA MONITOR AND RECORD menu NOTE: 1998 vehicles can be tested for MIL (PCM) and AFCM codes only All AFCM PIDS must be pulled with GFI card (Rotunda Part #164-R0904) and Cable (Rotunda part #164-R0906) PIDS are viewed by connecting the NGS to the J/108 connector at the VCL 1999 - 2002 Ford Dedicated CNG Vehicles March, 2002 Appendix - NGS APPENDIX NGS Parameter Identification Data (PID) Function (continued) BF 5-9 AFCM PID Screen A PID screen similar to the one shown here will appear To select an individual PID, first, use the scroll bar to highlight the PID you wish to select, then press trigger An asterisk will appear next to the PID, indicating that it has been selected for viewing and recording To select a BLOCK (group) of PIDs at the same time, press the BLOCK button (button 6), and then press TRIGGER As you rotate the scroll bar through the PIDs, they will be highlighted When you have highlighted the desired group, press TRIGGER again and asterisks will appear next to the selected PIDs To select the maximum number of PIDs for viewing, press the MAX button Press the START button and the PID values will appear You can now watch the signals to determine if they are acting normally, or if they could be the cause of the concern The NGS not only can monitor PID, but it can record it as well This function is very useful when driving a vehicle or when diagnosing an intermittent fault When you pushed the START button to view the PID data, the NGS began recording the data The NGS will continue recording PID data until the memory fills When the memory is full, the data at the beginning of the recording will drop off and new data will be stored The amount of time it takes to fill the memory will depend on the number and complexity of the PIDs selected Appendix - March, 2002 1999 - 2002 Ford Dedicated CNG Vehicles NGS APPENDIX NGS Parameter Identification Data (PID) Function (continued) 10 Along the bottom of the screen the instructions tell you to press trigger to CAPTURE data: Once the trigger is pressed, the NGS will continue to record data However, data at the beginning of the recording will not drop off The NGS will continue to save data until you press TRIGGER again to SAVE the data, or until recorder memory is full In this way, the NGS will have data in memory both before and after you pressed the TRIGGER to CAPTURE data For example, assume you are driving a vehicle with a poor performance concern and no DTCs are present – This pinpoint test specifies certain PIDs to view – Since you cannot view the PIDs and drive at the same time, you decide to record the PIDs during vehicle operation – Select the PIDs you wish to view (those specified by the test and any others you feel may be helpful) – While driving, you notice a sudden loss of engine power Press the trigger to capture the data – You can now drive the vehicle until the recorder memory is full or you can press the trigger again to save the data before the memory fills – Data will be saved from both before and after the trigger was pressed to capture data This allows you to see the data before, as well as after the concern occurred 1999 - 2002 Ford Dedicated CNG Vehicles March, 2002 Appendix - NGS APPENDIX NGS Parameter Identification Data (PID) Function (continued) BF 5-10 Saving a PID Recording 11 Once you press the trigger to save the data, a message will appear informing you that the data is being saved This screen will appear 12 Always store data before attempting to view the recording – Highlight the area of the NGS memory that you want to store the recording, then press TRIGGER – The NGS will warn you that any existing recording in that area will be overwritten 13 Press TRIGGER again and the data will be saved in the area you selected 14 To view the recording, select VIEW RECORDING area or return to the main menu 15 Highlight the VIEW RECORDING areas and press TRIGGER The NGS will ask you to select the recording area you wish to view 16 Highlight the area you wish to view and press TRIGGER 17 Once you have brought up the stored data, you need to select which sensor data you wish to view: Single Selection - To make a single selection, scroll to that selection and press TRIGGER An asterisk will appear before the selected PID MAX - The MAX button will select only the first or top four PIDs, regardless of the number that are available in the recording CLEAR - The CLEAR button will deselect all PIDs Appendix - 10 March, 2002 1999 - 2002 Ford Dedicated CNG Vehicles NGS APPENDIX NGS PID Viewing Options BF 5-11 PID Table Display Once you have selected a PID or several PIDs to view, you need to choose how you want to view them The options are table display and graph display Either of the two formats can be printed as well TABLE DISPLAY: The table display will allow you to view up to four of the recorded PIDs at a time, at various speeds The “Point-in-Time” recording will display on the left side of the screen To move forward through the recording, turn the scroll dial clockwise To move backward through the recording, turn the scroll dial counterclockwise Time 0.0 (T) is the point in the recording at which the data were captured (trigger pressed) A minus sign (-) in front of a number designates it as the time before capture The PIDs being viewed are displayed across the top of the screen with their respective values underneath them Review of the captured data is controlled by the specific functions displayed above the corresponding numeric keypad button – INFO - The INFO button will display the information screen This screen contains information about the recording, such as recording area, vehicle, type of link, TRIGGER point, type of module, and recording size – REW - The REW button will move backward through the recording at fast speed – STOP - The STOP button will stop the playback of the recording – PLAY - The PLAY button will move forward through the recording at normal speed – FWD - The FWD button will fast-forward the recording 1999 - 2002 Ford Dedicated CNG Vehicles March, 2002 Appendix - 11 NGS APPENDIX NGS PID Viewing Options (continued) BF 5-12 NGS Graph Display GRAPH DISPLAY: The graphing capability of NGS allows you to make visual comparisons between closely related PIDs so that you may determine whether or not their interaction is correct It also allows you to see a “glitch” that is not obvious on the table format Just as with the table display, up to four PIDs can be selected for graphing, but only two at a time can be displayed When the graph display appears on the screen, the names of the two currently selected PIDs will appear - one on the right and one on the left If more than two PIDs have been selected for viewing, you can change what is displayed on the screen by using the numeric keypad To change the left-hand PID, push number on the numeric keypad To change the right-hand PID, push the number on the numeric keypad The graph display screen will display a section of the recording that represents a portion of the recording The PIDs currently being viewed are displayed to the left and right sides of the screen There will be three sets of numbers also located to the left and/or right side of the screen These numbers refer to the following: – The top number represents the value of the PID at the beginning of the recording – The middle number shows the value of the PID where the vertical cursor is positioned – The bottom number represents the value of the PID at the end of the graph – To move the vertical cursor to the left, turn the scroll dial counterclockwise or clockwise The following functions are displayed on the screen just below the graph: – The - Time button (3) will move the screen toward the beginning of the recording – The + Time button (8) will move the screen toward the end of the recording Appendix - 12 March, 2002 1999 - 2002 Ford Dedicated CNG Vehicles GLOSSARY GLOSSARY The following is a list of terms and acronyms used throughout this book AFCM Alternative Fuel Control Module AFS Alternative Fuel System AFV AUX Alternative Fuel Vehicle Auxiliary B+ Battery Voltage BARO Barometric Sensor BASE VEHICLE The gasoline operating system of the vehicle BAUD-RATE Baud-rate refers to how many bits per second we can send over a connection BI-FUEL VEHICLE A vehicle that can operate on two different types of fuel (LPG and gasoline) BIT Binary Digit The NGS uses BIT to describe the amount of information it can process at one time CAUSE or PID that indicates reason vehicle changes fuel operating mode (LPG to GAS Gas to LPG) CFH Cubic Foot per Hour CHT Cylinder Head Temperature CGA Canadian Gas Association CLCF Closed Loop Correction Factor (1998 and earlier MY) CL_COR Closed Loop Correction Factor (1999 and later MY) CLEAN AIR ACT The clean air act requires the installation of more advanced pollution control equipment and changes to industrial operations and even community life-style that will lead to reductions in emissions of air pollutants COM Common COMPUVALVE The compuvalve uses preprogrammed strategies to control operation of the alternative fuel system on a bi-fuel vehicle It then meters fuel flow going into the engine CSH Cold Start Heater DATA BUS The wire(s) that run between control modules over which the modules communicate DEDICATED VEHICLE A dedicated vehicle uses only CNG for fuel DLC Data Link Connector DTC Diagnostic Trouble Code DVOM Digital Voltage and Ohm Meter ECT Engine Coolant Temperature EEC-V Electronic Engine Control Version 1999 - 2002 Ford Dedicated CNG Vehicles March, 2002 Glossary - GLOSSARY GLOSSARY (continued) EFT Engine Fuel Temperature EGR Exhaust Gas Recirculation ENERGY POLICY ACT The energy policy act provides for improved energy efficiency It includes provisions to allow for greater competition in energy sales ETHYL MERCAPTAN A scent that is added to LPG for safety and leak detection EVTM Electrical Vacuum Troubleshooting Manual FORD TECHNICAL SERVICE HOTLINE 1-800-826-4694 FAP Fuel Absolute Pressure (98 and earlier MY) FRPREAB Fuel Absolute Pressure (99 and later MY) FRTMPAB Engine Fuel Temperature Bank FTTMP Signal Recieved from the Fuel Tank Temperature Sensor FCV Fuel Control Valve FRP Fuel Rail Pressure FRT Fuel Rail Temperature FRPBREAB Fuel Absolute Pressure (99 and later MY) FSP Fuel Storage Pressure FTP Fuel Tank Pressure FTT Fuel Tank Temperature FUEL_MODE Fuel Operating Mode (LPG or GAS) GFI Gaseous Fuel Injection HD5 Ford requires the LPG fuel used in there systems to meet HD5 standards HD5 limits the amount of propene (a different type of gas than propane) that may be in the LPG mixture Too much propene can lead to plastic-like deposits to form in the fuel system HD10 In California Ford requires the LPG fuel used in there systems to meet HD10 standards The difference between HD10 and HD5 is the amount of propene (a different type of gas than propane) that may be in the LPG mixture Too much propene can lead to plastic-like deposits to form in the fuel system HO2S Heated Oxygen Sensor IAT Intake Air Temperature KOEO Key On Engine Off KOER Key On Engine Running KPA KiloPascals Absolute LCD Liquid Crystal Display LED Light Emitting Diode LPG Liquefied Petroleum Glossary - March, 2002 1999 - 2002 Ford Dedicated CNG Vehicles GLOSSARY GLOSSARY (continued) MAF Mass Air Flow MAP Manifold Absolute Pressure MIL Malfunction Indicator Lamp MULTIPLEXING NFPA A computer strategy that allows module-to-module communication during normal vehicle operation National Fire Protection Association NGS New Generation STAR OBD On-board Diagnostics OPMODE Operating Mode PC/ED Powertrain Control/Emission Diagnosis PCM Powertrain Control Module PCV Pressure Control Valve PD Preliminary Diagnostics PID Parameter Identification PROTOCOL A computer language that allows communication between control modules PSI Pounds per Square Inch PWM Pulse Width Modulated RCV Regulator Control Valve RPM Revolutions Per Minute SELSW Fuel Selector Switch Position SIG Signal SIG RTN Signal Return SPDT Single Pole Double Throw SSCC Symptom-to-System-to-Component-to-Cause STOICHIOMETRIC Ideal air/fuel ratio SW B+ Switched Battery Voltage TPS Throttle Position Sensor TSB Technical Service Bulletin VCL Vehicle Communications Link VECI Vehicle Emissions Control Information VIN Vehicle Identification Number VSS Vehicle Speed Sensor WOT Wide Open Throttle 1999 - 2002 Ford Dedicated CNG Vehicles March, 2002 Glossary - GLOSSARY NOTES Glossary - March, 2002 1999-2002 Ford Bi-Fuel Vehicles TOOL LIST ROTUNDA TOOL LIST AND ORDER FORM The tools listed below were used during the presentation of this course It is essential that correct tools be used during transmission service and repair For your convenience, the tools are listed below and a Rotunda Order Form can be found on the following pages New Generation STAR (NGS) Tester 007-00500 Digital Multimeter 007-00001 104-pin Breakout Box 014-00950 Spring Lock Coupling Disconnect Tools D87L-9280-A Spring Lock Coupling Disconnect Tool D87L-9280-B Spring Lock Coupling Disconnect Tool T83P-19326-C Contour Vent Kit 164-R0911 Rotunda Natural Gas Service Kit 134-00254 (Contents include the following:) – Manual Override Tool 134-00050 – Fuel Fill Valve Filter Remover/Installer Tool 134-00115 – Fuel Rail Pressure Test & Venting Kit 134-00116 – Fuel Filler Neck Venting Tool 134-00117 – Venting Hose 134-00118 – Electronic Fuel Injector Tester 134-00119 – Electrical Harness for Venting Tanks 134-00120 – Grounding Cable 134-00121 – Vent Box - Pressure Test Adapter 134-00122 – Electronic Leak Detector 134-00049 – E&F Series CNG Venting Adapter 134-00225 Rotunda Gaseous Fuel Service Kit 164-R0912 (Contents include the following:) – NGS Tester Program Card 164-R0905 – NGS Tester Adapter Cable 164-R0906 – Fuel Pressure Sensor R&I Tool 164-R0906 – Tank Valve Wrench 164-R0908 – Tank Solenoid Ring Wrench 164-R0909 – Tank Solenoid Valve Core Wrench 164-R0910 – Venting Kit 164-R0911 1999-2002 Ford Bi-Fuel Vehicles TOOL LIST 1999-2002 Ford Bi-Fuel Vehicles ORDER FORM ITEM NUMBER QTY PREFIX BAL OF NO PART I ADDITIONAL SPECIFICATIONS (if required) COL COL OPTIONAL: CATALOG PAGE NO FAX NUMBER 1-800-762-6181 DESCRIPTION EXTENDED TOTAL UNIT PRICE TOTAL PART II Buyer, having been quoted both an installment Price and a lesser Cash Price, hereby purchases from Seller on installment price basis, upon the terms and conditions set forth on the face hereof, the equipment to be delivered and installed at Buyer’s premises, as described above and agrees to pay Seller the Installment Price therefore as so set forth until paid in full Dealer Parts Code #: Dealer Name: Address: ❏ 30 Day Open Account City, State, Zip: Installment Plan (Fixed Rate) ❏ 12 Mo (Minimum $1,000) ❏ 24 Mo (Minimum $3,000) ❏ 48 Mo (Minimum $10,000) ❏ 60 Mo (Minimum $15,000) (Reverse side must be completed) Phone #: Fax #: PART III ❏ 36 Mo (Minimum $5,000) Attention: (ORDERS OVER $4,000) FCSD CREDIT MANAGER APPROVAL Notice To Buyer: Order Date: Ship to arrive by (Date or ASAP): Address: City, State, Zip: Do not sign this contract before you read it or if it contains any blank spaces You are entitled to an exact copy of the contract you sign Under the law you have the right to pay off in advance the full amount due and under certain circumstances to obtain partial refund of the time charge BUYER ACKNOWLEDGES RECEIPT OF A TRUE AND COMPLETELY FILLED IN COPY OF THIS CONTRACT AT THE TIME OF SIGNING May 2000 315-195 Prices subject to change without notice PRINT NAME AUTHORIZED DEALERSHIP SIGNATURE (BUYER) DEALER: Be sure you have completed Parts I and II for all orders, Part III for Installment Plan Orders 315-195 (Previous editions may not be used) FOR TELEPHONE ORDERS USE THE ROTUNDA TOLL-FREE NUMBER 1-800-ROTUNDA (768-8632) TERMS & CONDITIONS Payment and Terms of Payment a If Buyer has requested the Dealer Open Account payment plan via the Ford Dealer Statement in Part II of the order form, and Seller agrees to sell pursuant to such plan, then Buyer shall pay the total purchase price shown on the invoice b If Buyer has requested the Installment Plan (Fixed Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Down Payment (if any), and the Time Balance in equal monthly installments in accordance with the terms set forth below c If Buyer has requested the Installment Plan (Variable Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Total Cash Price and any interest thereon in accordance with the Loan and Security Agreement to be executed by Buyer and Seller Title Title to Equipment purchased by Buyer from Seller shall pass to Buyer upon Seller’s receipt of all amounts owing by Buyer to Seller hereunder Risk of Loss Seller shall be responsible for risk of loss until Equipment is delivered to the location set forth herein, at which time risk of loss shall be the responsibility of Buyer Acceptance and Inspection Buyer shall be deemed to have accepted Equipment upon Seller’s delivery Equipment shall be deemed to have been delivered in good condition unless Buyer gives Seller notice to the contrary within 10 days after Seller’s delivery Delays Seller shall not be liable for any failure or delay in delivering Equipment, or for any failure to perform any provision hereof, resulting from fire, flood or other casualty, riot, strike or other labor difficulty, governmental regulation or other restriction, or any other cause beyond Seller’s control Unconditional Obligation Buyer’s obligation to make payments to Seller or its assignee shall be absolute and unconditional and shall continue unmodified despite any loss, damage or other interruption in the use of Equipment The obligation of Buyer to pay in full any amounts due under this contract shall not be subject to dispute, claim, counterclaim, defense or other right which Buyer may have to assert against Seller or the manufacturer of Equipment Buyer acknowledges that: (a) Buyer has selected Equipment and Manufacturer, and Buyer has determined Equipment’s suitability and fitness for the Buyer’s purpose, (b) Seller is not the manufacturer of Equipment, and (c) Manufacturer issues its own warranty and performs the obligations under such warranty Warranty THE MANUFACTURER’S WARRANTY SHALL BE BUYER’S EXCLUSIVE REMEDY, RECOURSE OR DAMAGE FOR ANY DEFECT IN WORKMANSHIP OR MATERIAL OR ANY FAILURE OF THE EQUIPMENT SELLER MAKES NO WARRANTIES, REPRESENTATIONS, INDEMNITIES OR GUARANTEES WHATSOEVER WITH RESPECT TO EQUIPMENT EITHER EXPRESS OR IMPLIED, ARISING BY LAW OR CUSTOM, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THE LIABILITY OF THE SELLER SHALL BE LIMITED TO EXPRESS OBLIGATION TO DELIVER THE EQUIPMENT UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE OR RESPONSIBLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, WHETHER FORESEEABLE OR UNFORESEEABLE, WHICH BUYER MAY INCUR, EXPERIENCE OR CLAIM, INCLUDING, BUT NOT LIMITED TO, CLAIMS FOR LOSS OF PROFITS, INTERRUPTION IN BUSINESS, LOST OPPORTUNITY, WORK STOPPAGE OR OTHER IMPAIRMENT OF ASSETS, ARISING OUT OF MISREPRESENTATION, NEGLIGENCE, STRICT LIABILITY, IN TORT OR OTHERWISE, ON ACCOUNT OF ENTERING INTO OR RELYING ON THIS AGREEMENT, EVEN IF SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES Freight and Taxes Freight costs and applicable taxes will be added to the final invoice and will be borne by Buyer Security Interest Buyer hereby grants to Seller a continuing security interest in the Equipment, including all products and proceeds thereof, until all amounts due hereunder are paid Buyer agrees to execute, and pay filing fees for, any financing statement or other documents deemed necessary by Seller to maintain a valid security interest in the Equipment 10 Maintenance Buyer shall use the Equipment carefully and properly Buyer, at Buyer’s own expense, shall maintain and repair all items of the Equipment in order to keep them in good order and condition and, in particular, shall comply fully with the maintenance, operating, usage or other instructions provided by the manufacturer Buyer authorizes Seller, or any third party appointed by Seller, to inspect the Equipment when necessary Buyer shall at all times keep the Equipment free and clear of all liens, charges or encumbrances 11 Personal Property Ford proprietary diagnostic equipment (including the software, if applicable) shall be kept at Buyer’s premises as listed on the reverse side and shall remain personal property regardless of how and to what degree it may be affixed or attached to any building or structure or what may be the consequence of its removal from such building or structure Buyer shall not encumber the Equipment (including software, if applicable) until all amounts owing to Seller hereunder are paid In addition, Seller grants to Buyer, and Buyer accepts, a non-exclusive license to use the Equipment (including the software, if applicable) in accordance with the terms and conditions set forth herein The license (and Equipment) shall not be leased, sold, assigned or otherwise transferred, in whole or in part In the event, Buyer proposes to lease, sell assign or otherwise transfer the Equipment (and/or its software, if applicable), in whole or in part, to any person or entity, Ford Motor Company shall have a Right of First Refusal to purchase the Equipment (including all software, if applicable) for Ten and 00/100 Dollars ($10.00) in U.S currency 12 Insurance and Indemnification Buyer shall defend, indemnify and hold harmless Seller from and against, and at Buyer’s own expense provide insurance satisfactory to Seller covering any and all losses, damages, claims, expenses and other liabilities (including attorney’s fees,) relating to or arising out of: (I) damage, loss, theft, or destruction of the Equipment, or (ii) death, injury or property damage connected with the use, operation or condition (including without limitation, defects whether or not discoverable by any party) of the Equipment Buyer shall promptly notify Seller of any such claim Seller shall have the right to participate, at its own expense, in any proceeding for which Buyer has undertaken the defense of Seller, and in no event shall Buyer settle any claim against Seller without Seller’s prior written consent, Buyer shall provide evidence of such insurance to Seller upon demand Seller is under no obligation to examine any insurance certificate or advise Buyer that its insurance does not comply with the requirements set forth herein The losses covered by insurance shall in all cases be payable to Seller and Buyer as their interests may appear If Buyer fails to insure the Equipment as herein provided, Seller may, but is not obligated to, place such insurance upon the Equipment and the Buyer agrees to pay to Seller on demand the premiums for such insurance placed by Seller In no event shall any insurance coverage be deemed to limit or replace Buyer’s obligation to indemnify Seller as provided herein 13 Default In the event that Buyer: (a) fails to pay any amount due hereunder within ten (10) days of the due date, (b) fails to comply with any other provision hereof, (c) files, or if there is filed against Buyer, any petition under any bankruptcy or insolvency laws or suffers the appointment of any trustee or receiver for all or any part of Buyer’s business or assets, or (d) has any assignment (voluntarily or involuntarily), lien, attachment or levy issued against the Equipment (unless such petition, assignment or appointment, lien, attachment or levy is withdrawn or nullified within twenty (20) days) then Buyer shall be in default hereunder and all of Buyer’s indebtedness and obligations to Seller shall, at Seller’s option, become immediately due and payable, and Seller may, at its option, terminate this contract and repossess any and all items of Equipment with or without legal process and sell the same at private or public sale without prior notice to Buyer to the extent permitted by law Upon request, Buyer shall deliver the Equipment to Seller at a place designated by Seller Repossession and/or sales of the Equipment upon such default shall not affect the Seller’s right to retain all payments made prior to repossession or to recover the balance due hereunder for any deficiency Buyer shall reimburse Seller all costs of collection, repossession and resale (including reasonable attorneys’ fees, court costs and other expenses incurred by Seller.) Buyer hereby releases Seller from any liability for damages resulting from repossession hereunder The rights and remedies of Seller, in the event of default herein mentioned shall not be deemed exclusive but shall be cumulative and in addition to all other rights and remedies existing under law, and may be enforced successively or concurrently Waiver by Seller of any default shall not be deemed a waiver of any other default 14 General The waiver by either party of, or failure to claim, a breach of any provision of this contract shall not be deemed to be a waiver of any provision of this contract, shall not be deemed to be a waiver of any subsequent breach or to affect in any way the effectiveness of such provision This contract constitutes the entire agreement between the parties and may not be changed except by an instrument in writing signed by the party to be charged This contract may not be assigned by Buyer without the Seller’s prior written consent Seller may assign this contract at any time but shall not thereby be relieved from any liability hereunder In the event that one or more clauses of this contract are found to be unenforceable, illegal or contrary to public policy by court of competent jurisdiction, the remainder of this contract shall remain in full force and effect except for the unenforceable, illegal or other provisions This agreement is a Michigan agreement and shall be interpreted, construed and enforced in accordance with the laws of the State of Michigan, United States of America Each of the parties here to agrees that any legal or equitable action or proceeding with respect to this agreement shall be brought only in any court of the State of Michigan, or in any court of the United States of America sitting in Michigan, and each of the parties hereto submits to and accepts generally and unconditionally the jurisdiction of those courts with respect to such party’s person and property Each party hereby irrevocably waives any objection to the laying of venue of any such action or proceeding in the above described courts 15 Finance Charge Monthly portion of Finance Charge (Part III, Item 3) due is calculated each month by multiplying 1/12 of the annual finance charge rate times the remaining portion of the Unpaid Balance of Cash Price, and is added to the portion of the Unpaid Balance of Cash Price due each month PART III Installment Plan Agreement Cash Price $ Down Payment (if any) $ Unpaid Balance of Cash Price (Difference between and 2) $ Finance Charge (Finance charge will reduce each month) Call 1-800-768-8632 for the current finance charge rate $ Time Balance (3 + 4) $ Number of Installments ❏ 12 ❏ 24 ❏ 36 ❏ 48 ❏ 60 equal monthly installments Taxes and transportation (if any) will be billed separately Installment Payment Price (1 + 4) $ I agree to pay the time Balance set forth in accordance with the above schedule and the terms and conditions of this order form Dealer Signature: Date: MAIL COMPLETED ORDER FORM TO: ROTUNDA EQUIPMENT PROGRAM P.O Box 1450 Kenosha, WI 53141 September 1999 315-195 Prices subject to change without notice ... soap and water 1999 - 2002 Ford Dedicated CNG Vehicles March, 2002 Intro - INTRODUCTION AND PREREQUISITE REVIEW DAY ONE NOTES Intro - 10 March, 2002 1999 - 2002 Ford Dedicated CNG Vehicles LESSON... Regulator 16 March, 2002 1999 - 2002 Ford Dedicated CNG Vehicles LESSON 2: DEDICATED CNG VEHICLE OPERATION DEDICATED CNG VEHICLE THEORY OF OPERATION (continued) Dedicated CNG vehicles can be equipped... March, 2002 1999 - 2002 Ford Dedicated CNG Vehicles LESSON 2: DEDICATED CNG VEHICLE OPERATION DEDICATED CNG FUEL SYSTEM THEORY AND OPERATION (continued) The dedicated CNG fuel system on Ford vehicles