Altech-Eco CNG Installation Manual

2018 ford f-150 5.0l

Hide thumbs

page of 39

/ 39
Bookmarks

Quick Links

Download this manual

CNG CONVERSION SYSTEM INSTALLATION MANUAL

2018 FORD F-150 5.0L

COMPLETE BI-FUEL CNG SYSTEM

Updated: 4/19/2018

Need help?

Do you have a question about the CNG and is the answer not in the manual?

Questions and answers

Summary of Contents for Altech-Eco CNG

Page 1 CNG CONVERSION SYSTEM INSTALLATION MANUAL 2018 FORD F-150 5.0L COMPLETE BI-FUEL CNG SYSTEM Updated: 4/19/2018...
Page 2 • Use extreme caution and follow all related safety guidelines. We have tried to make this installation as safe as possible but we can not predict all scenarios. • This CNG system requires gasoline in vehicle at all time–ate on CNG. When the low gasoline level indicator light illuminates the CNG system will automatically turn off until additional gasoline is fueled into the vehicle and the low level light turns off.
Page 3 1. Confirm packing slip to insure that you have received all components, assemblies, and sub-assemblies. 2. Make sure none of the components and assemblies have been damaged during shipping. 3. Pre-inspect the vehicle following the QVM, Q-185, and NFPA 52 regulations (Contact ALTECH-ECO for the inspection check list). 4. Begin your conversion process.
Page 4 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS Attaching Accessories to Aluminum Panels and Structure Approved Fasteners  Q-222  Aluminum Clamps  Plastic Scrivets  Aluminum Rivnuts  Aluminum Pop Rivets  Plastic Push Pins  Zinc coated steel fasteners used with an aluminum washer SVE BULLETIN Isolator Recommendations SPECIAL VEHICLE ENGINEERING –...
Page 5 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the CNG system installation is complete, reconnect the fuel pump control module electrical connector. 8. Cycle the ignition key and wait 3 seconds to pressurize the fuel system.
Page 6 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS CYLINDER INSTALL - 5.5’ SHORT BED / 6.5’ SHORT BED (18” x 60” CYLINDER) 1. Use the template layout and measure out each drill point. Mark the holes in shown locations. Always verify your measurements before drilling. 2.
Page 7 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS CYLINDER INSTALL - 6.5’ SHORT BED (21” x 60” CYLINDER) 2 016-2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM Drill Template - 6.5’ SHORT BED - 21 x 60 Cylinder. 1.
Page 8 2016-2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS 2016-2018 F-150 5.0L Drill Template - 8’ LONG BED CYLINDER INSTALL - 8’ LONG BED (21” x 60” CYLINDER) For 21 x 60 Cylinder. 1.
Page 9 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS CYLINDER INSTALL - 6.5’ SHORT BED & 8’ LONG BED 1. Install grommet. 2. Remove the two or four Ford front bed bolts and discard. 3. With a hoist, lower the pre-assembled cylinder package in the bed of the truck. Be careful not to damage the bed walls.
Page 10 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS CYLINDER INSTALL - 6.5’ SHORT BED / 8’ LONG BED • Connect low pressure fuel hose to the regulator. Torque to 30-35 ft-lbs. See low pressure hose install section for details. •...
Page 11 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS FUEL FILL INSTALLATION - SIDE MOUNT FOR 5.5’ BED 1. Measure 6” (horizontal) x 16” (vertical) and mark the drill point. 2. Drill a 1/4” pilot hole first. Double check your measurements. Then using a hole saw, drill a 2 9/16” hole. Use caution when drilling so as to not damage surrounding area.
Page 12 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS FUEL FILL INSTALLATION - SIDE MOUNT FOR 6.5 FT BED 1. Measure 16” (horizontal) x 16” (vertical) and mark the drill point. 2. Drill a 1/4” pilot hole first. Double check measurements. Then using a hole saw, drill a 2 9/16” hole. Use caution when drilling so as to not damage surrounding area.
Page 13 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS FUEL FILL INSTALLATION - SIDE MOUNT FOR 8 FT BED 1. Measure 34” (horizontal) x 16” (vertical) and mark the drill point. 2. Drill a 1/4” pilot hole first. Double check measurements. Then using a hole saw, drill a 2 9/16” hole. Use caution when drilling so as to not damage surrounding area.
Page 14 1. Obtain the fuel fill cup and joining components. Remove the rubber cap and the nut from the receptacle. Rubber cap is to be re-attached when as- CNG Receptacle sembly is completed. 2. Insert receptacle through fuel fill cup housing opening and screw nut on receptacle.
Page 15 Fuel fill ring screw Used with the long bed Re-attach the rubber dust cap over the receptacle. 5/8” P-clamp Self tapping screw Attach the CNG Only sticker inside the fuel fill cup. Page 15 2018 F-150 5.0L INSTALLATION MANUAL...
Page 16 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS LOW PRESSURE INSTALLATION Disconnect connections and remove air intake hose/tube. Disconnect these three hoses on this end and set aside. Remove foam insulation and discard. Disconnect all OEM connectors from the injectors. DO NOT USE POWER TOOLS! Page 16 2018 F-150 5.0L INSTALLATION MANUAL...
Page 17 Remove and save the four OEM fuel rail bolts. Remove OEM fuel rails along with the injectors and discard. Remove and save OEM pressure temperature sensor. Note: Rails contain gasoline. Install CNG injectors unto the CNG fuel rails. Page 17 2018 F-150 5.0L INSTALLATION MANUAL...
Page 18 Route the hose towards the back of the manifold facing the cabin. Zip tie the temp/pressure sensor, fitting, and gasoline port assembly to the CNG to fuel rail. Tighten zip tie to the fuel rail. Page 18 2018 F-150 5.0L INSTALLATION MANUAL...
Page 19 CNG injectors. Connect OEM harness to the OEM temp/pressure sensor. Connect CNG low pressure hose (once installed) to the fuel rail. Ensure each end of the hose is labeled with a low pressure sticker. Reconnect all OEM air hoses and place back the air intake hose/ tube.
Page 20 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS WIRING - PIG TAIL Remove middle PCM connector. Remove connector back cover and any protective tape near to expose the wire. Save tape for re-use. Remove front face plate to expose the terminals. This face plate is numbered. Set aside to use as a reference when locating a terminal.
Page 21 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS WIRING - PIG TAIL Locate OEM pin 31 (Green) wire. Cut the wire, about 2-3 inches from the PCM connector. Using shrink tube, cap off the green wire end going through into the rest of the OEM harness.
Page 22 Shrink tube the splice and re-install the terminal back into its original location. Re-attach front face plate, rear cap, and re tape to hide any exposed wires. Plug PCM connector back in, and plug pig tail into CNG harness when appropriate. Page 22...
Page 23 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS WIRING - CNG HARNESS Route as shown and zip tie every 1 - 1 1/2 feet, or loose areas. See next page for the fuse box install. FUSE BOX...
Page 24 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS WIRING - CNG HARNESS (FUSE BOX) Locate OEM stud located on the passenger side and above the engine. Use a provided nut and install fuse box bracket onto OEM stud.
Page 25 This hole will be used for the harness leading into the engine compartment. Drill a 7/8” hole. Rust proof and de burr. Feed the gauge harness through the hole and into the engine compartment. Secure the harness grommet. Attached to the main CNG harness Page 25 2018 F-150 5.0L INSTALLATION MANUAL...
Page 26 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS FUEL GAUGE ROUTING and INSTALL PREPARATION: REMOVE SHOWN PLASTIC PANELS, COVERS, AND CAPS FIRST. See below. Remove the caps and unscrew the OEM bolts, save for reuse. Loosen the rubber strip and remove the driver side A pillar. Detach top of the control panel without removing it.
Page 27 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS FUEL GAUGE ROUTING and INSTALL Retrieve the gauge pod, and enlarge hole to 3/4”. Insert the gauge wires through the pod hole and combine gauge with pod. Ensure the rubber o-ring is also placed over the gauge housing. Insert gauge into pod.
Page 28 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS FUEL GAUGE ROUTING and INSTALL Re-install and reattach all OEM panels along with the A pillar containing the gauge, and remember to connect the gauge wires to the CNG gauge harness. Page 28 2018 F-150 5.0L INSTALLATION MANUAL...
Page 29 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS LOW PRESSURE HOSE ROUTING / QUARTER TURN VALVE Route along the frame as shown. Connect one end to the regulator and other end to the fuel rail. Tighten each end to 35 ft-lbs of torque. Verify proper routing first before securing. Install 5/16”...
Page 30 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS LOW PRESSURE HOSE ROUTING / QUARTER TURN VALVE Continued... Page 30 2018 F-150 5.0L INSTALLATION MANUAL...
Page 31 3. Insert one straight connector (80651) per each cut hose end, two connectors in total (Fig. E). 4. Slide a hose clamp on each end of all 4 hose ends (CNG and Ford) to get ready for final connections. 5. The CNG coolant hose identified with colored tape connects to the Ford coolant hose coming out of the engine and the IN port on CNG regulator.
Page 32 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS COOLANT HOSE ROUTING CONTINUED Page 32 2018 F-150 5.0L INSTALLATION MANUAL...
Page 33 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS REAR HARNESS ROUTING 1. Route rear harness along same path as the low pressure hose and zip tie any slack in the wire. 2. Connect rear harness to high pressure sensor and cylinder valve automatic solenoid. Two connections: HP Sensor and Solenoid Page 33 2018 F-150 5.0L INSTALLATION MANUAL...
Page 34 7. Attach sticker (P/N: G-D0609), one on the inside of the cover and one on the cylinder strap closest to the valve. 8. Place cover back into place and secure with 6 1/4” - 20 x 1” bolts. 9. Center and place the Altech-Eco logo sticker on toolbox. NOTE: Perform a leak check first before placing cover!! Page 34 2018 F-150 5.0L INSTALLATION MANUAL...
Page 35 Place cover decal inside the cylinder cover and one on cylinder strap closest to the valve. Place skirt into place and secure with eight 1/4-20 x 1” bolts. Center and place Altech-Eco logo decal on toolbox. NOTE: Perform a leak check first before placing cover!!
Page 36 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS DECAL PLACEMENT Remove the word “E-85” from the gasoline filler. Passenger side door Driver side door Remove flex fuel decal. Passenger side Driver side Page 36 2018 F-150 5.0L INSTALLATION MANUAL...
Page 37 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS DECAL PLACEMENT NOTE: All high pressure hoses must be labeled with a high pressure sticker. Page 37 2018 F-150 5.0L INSTALLATION MANUAL...
Page 38 After the Altech-Eco CNG system has been installed on the vehicle, all coolant hoses and connections, all gasoline and CNG connections, gasoline and CNG fuel rails and injectors must be checked for leaks. Also, check the overall installation of wiring, zip ties and other components to make sure they are not loose or hanging.
Page 39 2018 FORD F-150 5.0L COMPRESSED NATURAL GAS CONVERSION SYSTEM INSTALLATION INSTRUCTIONS Contact Information For technical support: • Phone: 828-654-8300 • E-mail: customerservice@altecheco.com For sales questions: • Phone: 828-654-8300 • E-mail: miles@transecoenergy.com Altech-Eco Address: • 101 Fair Oaks Road, Arden NC 28704 Page 39 2018 F-150 5.0L INSTALLATION MANUAL...