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ROUSH Ford F-150 Service Manual Supplement

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2007.5 - 2008
Ford F-150
LIQUID PROPANE INJECTION
Rev. 12/14/2010
SERVICE MANUAL SUPPLEMENT

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Questions and answers

Dale Kirtley
January 22, 2025

I would like to disable a feature but I’m not even sure what it’s called. If my truck is running and I walk away with the key fob in my pocket, the horn beeps twice. How do I disable this feature?

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1 comments:
Mr. Anderson
May 14, 2025

You can disable the double horn honk on your Ford F-150 when walking away with the key fob while the truck is running by using a programmer. Plug the programmer into the diagnostic port, wait until it turns green, then remove it. After restarting the vehicle and walking away with the fob, the horn honk will be disabled. To re-enable the feature, repeat the process with the programmer.

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Summary of Contents for ROUSH Ford F-150

  • Page 1 2007.5 - 2008 Ford F-150 LIQUID PROPANE INJECTION Rev. 12/14/2010 SERVICE MANUAL SUPPLEMENT...

  • Page 2: Limited Liability Disclaimer

    Service Manual Supplement FOREWORD This manual is a supplement to the Ford F-150 Workshop Manuals (referenced as the “Ford WSM” where applicable in this manual). It is intended to provide technicians with the procedures required to maintain and service the unique components of the ROUSH CleanTech F-150 Liquid Propane Injection vehicles.

  • Page 3: Table Of Contents

    Service Manual Supplement TABLE OF CONTENTS FOREWORD......................i LIMITED LIABILITY DISCLAIMER.................i INTRODUCTION.....................1 General Information...................1 ROUSH CleanTech Technical Assistance ..............1 Start Sequence ......................... 1 Fill Stations ........................1 Range and Fuel Economy....................2 Safety Information .....................2 Alert Messages ......................... 2 Installation, Garaging and Training ..............3 Purging and Venting (Tanks and Lines)............3...
  • Page 4 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement COMPONENT LOCATOR..................15 Engine Compartment ..................15 Fuel Rails and Injectors ....................15 Chassis ......................16 Fuel Lines and Tanks ..................... 16 TROUBLESHOOTING ..................17 Symptom Tables ....................17 Fuel Odor......................... 17 Diagnostic Flow Charts...................18 No Fill Condition......................
  • Page 5 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Installing Intake Airbox Cover ..................46 Fuel System Component Removal Procedures ...........47 Removing Pressure Relief Hose ................... 47 Removing Flow Control Solenoid ................. 48 Removing Fuel Lines (In-Bed Tank to Solenoid) ............48 Removing Fuel Lines (Under-Vehicle Toroidal Tank to Solenoid) ......
  • Page 6 Installing Fuel Lines (In-Bed Tank to Solenoid)............85 Installing Flow Control Solenoid................... 85 Installing Pressure Relief Hose ..................86 SPECIFICATIONS ....................87 Engine Specifications ..................87 ROUSH CleanTech Conversion Ford 5.4L LPI Engine ..........87 Chassis Specifications..................87 Fastener Torque Values ..................88 SCHEMATICS ......................90 Fuel System Flow Diagrams................90 Fuel Flow.........................

  • Page 7: Introduction

    • Fuel filler lines, valve and filter • Fuel tank The ROUSH CleanTech parts generally serve the same functions as the Ford parts they replace. The online Ford Workshop Manual, if available, continues to apply to all other details. The diagnostic chart in this manual directs the technician to appropriate sections of the Ford manual for applicable remedies in some situations.

  • Page 8: Range And Fuel Economy

    CleanTech F-150 Liquid Propane Injection Service Manual Supplement ROUSH CleanTech recommends facilities designed for automotive refueling. Other locations may have low output pumps, resulting in slow or no fill, or low quality fuel which can result in premature component failure.

  • Page 9: Installation, Garaging And Training

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Installation, Garaging and Training Chapter 11 of NFPA 58 applies to engine fuel systems using LP-Gas in internal combustion engines, including containers, container appurtenances, carburetion equipment, piping, hose and fittings and their installation. Additionally, this chapter applies to garaging of vehicles and to the training of personnel.

  • Page 10: Vehicle Information

    VEHICLE INFORMATION Build Data ROUSH CleanTech emissions certification information is recorded on the ROUSH CleanTech Vehicle Emissions Control Information (VECI) label. The label is vehicle-specific and is required by law to be on the vehicle to which it is assigned along with the Ford VECI label.

  • Page 11: Veci Label Location

    CleanTech F-150 Liquid Propane Injection Service Manual Supplement VECI Label Location The ROUSH CleanTech VECI label appears along with the original Ford VECI label in the following location: • F-150 — under hood at front, driver side Figure 3 — VECI Label Location...

  • Page 12: Description And Operation

    DESCRIPTION AND OPERATION System Overview The ROUSH CleanTech Liquid Propane Injection (LPI) system consists of a propane fuel tank, fuel pump, fuel rails and lines, injectors and electronic controls. The system is simple and easily serviced with no user adjustment required.

  • Page 13: Vehicle Starting

    Vehicle Starting The ROUSH CleanTech LPI system is fully integrated using Ford’s One Touch Integrated Start (OTIS) system. When the ignition key is turned to crank and released to the On position, the PCM opens the Flow Control Solenoid (FCS) and engages the fuel pump. As soon as the fuel rail temperature and pressure are acceptable to ensure liquid fuel at the injectors, the starter engages and the vehicle starts with no further action required from the operator.

  • Page 14: System Components And Function

    System Components and Function Fuel Rails and Injectors The Ford OEM fuel rails and injectors are replaced with ROUSH CleanTech LPI fuel rail and injector assemblies, including injection pressure and temperature sensor (IPTS), Schrader port for service and crossover fuel line.

  • Page 15: Injection Pressure And Temperature Sensor (Ipts)

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Injection Pressure and Temperature Sensor (IPTS) The IPTS is used to monitor fuel pressure and temperature. On F-150 applications the IPTS is read directly by the PCM. Figure 7 — Injection Pressure and Temperature Sensor...

  • Page 16: Fuel Tanks

    Figure 9 — Fuel Tanks, Under-Vehicle Toroidal and In-Bed Configurations All ROUSH CleanTech LPI vehicle fuel tanks regardless of configuration are fitted with the same valve assemblies and control units. These include the Multivalve assembly, Fuel Control Solenoid, Fuel Fill Solenoid, 80% Level Sensor, Fill Pressure Switch and the Fuel Level Sending Unit.

  • Page 17: Multivalve

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Multivalve Wiring Pass-Through Overpressure Relief Manual Shutoff Supply Solenoid Fuel Fill Fuel Supply to Engine Fuel Return Figure 10 — Multivalve Assembly The Multivalve attaches directly to the fuel tank and serves as the main interface between fuel tank and vehicle.

  • Page 18: Fuel Level Sending Unit

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement FUEL LEVEL SENDING UNIT The Fuel Level Sending Unit is located inside of the fuel tank and consists of a float on an arm with a wound resistor. The sending unit resistance is used by the instrument cluster to indicate fuel level and by the PCM.

  • Page 19: Glossary

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Glossary 80% Level Sensor — An infrared sensor designed to detect the presence of liquid. The sensor is located inside the vehicle fuel tank at the 80% full level. Bleed Solenoid — Closed when the engine is running, sealing the fuel rail from the vehicle EVAP system.
  • Page 20 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Multivalve — Mounted directly on the vehicle fuel tank and serves as the main interface between fuel tank and vehicle. The Multivalve consists of five valves incorporated into one unit which includes the Fill Valve, the Manual Shutoff Valve, the Pressure Relief Valve, the Fuel Supply Valve and the Fuel Return Check Valve.

  • Page 21: Component Locator

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement COMPONENT LOCATOR Engine Compartment Fuel Rails and Injectors Figure 12 — Fuel Rails and Injectors Current as of 12-14-2010 12/14/2010...

  • Page 22: Chassis

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Chassis Fuel Lines and Tanks Figure 13 — F-150 Fuel Lines and Tank Current as of 12-14-2010 12/14/2010...

  • Page 23: Troubleshooting

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement TROUBLESHOOTING Symptom Tables Fuel Odor (Content to be developed) Current as of 12-14-2010 12/14/2010...

  • Page 24: Diagnostic Flow Charts

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Diagnostic Flow Charts No Fill Condition 1. VERIFY VEHICLE BATTERY IS FULLY CHARGED AND CONNECTED. Go to Step 2. a. Check battery connections and charge; repair as required. b. Attempt to fill vehicle fuel tank again.
  • Page 25 (Typically 300 psi or higher) Try another station Advise station owner to repair fuel delivery system. ROUSH CleanTech recommends 7.5hp pump for liquid automotive fills. Vehicle fuel tank may be hot enough to have an excessive amount of pressure if tank has been in direct sunlight or vehicle has been run for an extended period of time.
  • Page 26 Refer to schematic and (both positive and repair circuit as ground) in wire harness necessary from fuse box to fuel tank 6-pin connector NOT OPEN OPEN Repair circuit as Call ROUSH CleanTech necessary Warranty at 1.800.59.ROUSH. Current as of 12-14-2010 12/14/2010...
  • Page 27 CleanTech F-150 Liquid Propane Injection Service Manual Supplement 5. CHECK FOR SHORT CIRCUIT IN 12-VOLT SUPPLY TO FUSE BOX. Procedure 1. Verify ROUSH wire harness isn’t damaged. 2. Pin out to make sure short isn’t in the harness. HARNESS OK HARNESS DAMAGED...
  • Page 28 Note: Ammeter should read 0.7–0.95 amps if fuel fill circuit is activated. If ammeter reads near 0 amps, the fuel fill circuit is not activated and tank will not fill. AMMETER READS 0.7–0.95 AMMETER READS NEAR 0 AMPS AMPS Call ROUSH CleanTech Warranty Go to Step 8 at 1.800.59.ROUSH Current as of 12-14-2010 12/14/2010...
  • Page 29 Note: If any of the above problem conditions exist, the fuel fill switch will not close and will prevent the tank from filling. RESTRICTIONS AND/OR NO RESTRICTIONS OR PLUGGED FILTER PLUGGED FILTER Repair as necessary and retest Call ROUSH CleanTech Warranty at 1.800.59.ROUSH Current as of 12-14-2010 12/14/2010...

  • Page 30: Slow Fill Condition

    VEHICLE TANK PRESSURE. Preliminary check If this is the first fill after vehicle assembly or major fuel system repair, follow ROUSH CleanTech service “Flush and Fill Procedure for New Tank”. Note: If fill is EXTREMELY slow (less than 0.2 gallons per minute) and fill station pressure is acceptable (>50 PSI over tank), it may indicate that the fill circuit is not activated.
  • Page 31 AMMETER READS 0.7–0.95 AMMETER READS NEAR 0 AMPS OR INTERMITTENTLY AMPS DROPS CLOSE TO 0 AMPS Check fuel fill electrical circuit, Call ROUSH CleanTech Warranty repair as required and retest at 1.800.59.ROUSH Current as of 12-14-2010 12/14/2010...

  • Page 32: No Start Condition

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement No Start Condition 1. VERIFY VEHICLE BATTERY IS FULLY CHARGED AND CONNECTED. Go to Steps as necessary. a. Check battery connections and charge; repair as required. b. Attempt to fill vehicle fuel tank as necessary.

  • Page 33: Fuel Pump Diagnostics

    GENERAL INFORMATION The fuel pump should run continuously when the engine is cranking or running. The ROUSH CleanTech fuel pump relay in the mini relay box is controlled by the original Ford fuel pump circuitry including the Fuel Pump Driver Module and the Inertia Switch or Fuel Pump Interrupt software.
  • Page 34 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 4. CHECK FUEL PUMP PRESSURE Procedure 1. Connect pressure gauge (350 psi min) to bleeder valve on fuel tank. 2. Open bleeder valve and record gauge pressure reading for reference.
  • Page 35 0 VOLTS Check fuel tank wiring harness for damaged wires, Go to Step 6. pins or anything that may cause and “open” circuit. NOT OK HARNESS OK Call ROUSH CleanTech Repair harness and Warranty at retest. 1-800.59.ROUSH Current as of 12-14-2010...
  • Page 36 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 6. CHECK 20-AMP FUSE Figure 15 — Half-Fuse Box Procedure Visually check to see if the fuse is OK or if it is blown. The 20-amp fuse is in the number 2 position in the half fuse box.
  • Page 37 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement CHECK FUEL PUMP RELAY FUNCTION Check fuel pump relay function per the Ford On-line Workshop Manual and wiring diagrams. CHECK FUEL PUMP RELAY SUPPLY CIRCUIT Check fuel pump relay function per the Ford On-line Workshop Manual and wiring diagrams.
  • Page 38 Replace solenoid and for “Diagnostic Trouble retest. Codes (DTC’s) P009E OTHER DTC(s) NO DTC(s) Refer to FRPCM Repair according to Ford Call ROUSH CleanTech Diagnosis in this service Workshop Manual and Warranty at 1.800.59.ROUSH guide retest Current as of 12-14-2010 12/14/2010...

  • Page 39: Fuel Sending Unit Diagnostics

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Fuel Sending Unit Diagnostics 1. VERIFY VEHICLE BATTERY IS FULLY CHARGED AND CONNECTED. Go to Steps as necessary. a. Check battery connections and charge; repair as required. b. Attempt to fill vehicle fuel tank as necessary.
  • Page 40 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Procedure Turn the ignition switch to the off position if not already done. Disconnect the 6-pin fuel tank harness connector (located on fuel tank wire loom) from the vehicle harness.
  • Page 41 Figure 17 — ROUSH CLEANTECH-to-Ford 4-Pin Harness Connector (Typical) Procedure 1. With the ignition switch in the off position, disconnect the 4-pin connector where the ROUSH CleanTech harness attaches to the Ford vehicle harness. 2. Using the voltmeter on the Ford harness side of the connector, place the positive lead on the Yellow wire terminal and the negative lead on the Black/Orange wire terminal.

  • Page 42: Fuel Fill Table

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement CHECK RESISTANCE ACROSS TERMINALS OF FUEL SENDING UNIT Figure 18 — Fuel Sending Unit 6-Pin Connector Terminals Procedure 1. Place positive probe of ohmmeter on Yellow wire (Pin E) and negative probe on Black / Orange wire (Pin F).

  • Page 43: Maintenance Requirements

    Intake Air Filter Inspection Figure 19 — Intake Air Duct and Filter Housing (Typical) This intake air filter assembly is unique to the F-150 and is necessary for the ROUSH CleanTech LPI system. The ROUSH CleanTech intake air filter assembly replaces the original Ford assembly.

  • Page 44: In-Line Fuel Filter Replacement

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement In-Line Fuel Filter Replacement Danger — A trace amount of propane fuel will be released on loosening the fittings. It will settle to the lowest available surface before it dissipates into the atmosphere. Keep heat, sparks, flames, static electricity or other sources of ignition out of the area when venting or purging the fuel lines or tank.

  • Page 45: Repair Procedures

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement REPAIR PROCEDURES Preparing Vehicle for Service Alert Messages The following alert messages appear from time to time in appropriate places in this manual. Ensure that all personnel in the immediate area are aware of these reminders.

  • Page 46: Changing Fuses

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Changing Fuses Figure 21 — Fuse Panel The fuse panel is located on the bulkhead under the hood on the driver’s side. Figure 22 — 20 Amp and 15 Amp Fuses Always use a fuse of the correct amperage when replacing fuses.

  • Page 47: Pressure Relief

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Pressure Relief There are two means of relieving excess pressure in the tank; the pressure relief valve in the Multivalve and the bleeder valve in the tank wall that is separate from the Multivalve.

  • Page 48: Manual Fuel Shutoff

    Caution — If the 90-degree elbow or nut and tube assembly spins and cannot be removed, STOP and contact ROUSH CleanTech Customer Service at 800-597-6874. 4. With the cover removed, locate the manual shutoff valve. Turn the manual shutoff valve clockwise until it stops.

  • Page 49: Opening Manual Shutoff Valve

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Note — The manual shutoff valve can be hard to turn. From fully open to fully closed is approximately 2-1/2 turns. Figure 24 — Multivalve Assembly 1. Electrical Pass 5. Fuel Filler Inlet...

  • Page 50: Removing Intake Airbox Cover

    5. With Snoop®, or similar product, leak check the injectors, fuel rails and lines. Repair as necessary. 6. Start and run the engine and check for diagnostic trouble codes. Repair as necessary. Any questions, please contact ROUSH CleanTech Customer Service at 800-597-6874. Removing Intake Airbox Cover 1. Purge the propane from the fuel lines.

  • Page 51: Removing Power Steering Fluid Reservoir

    3. Disconnect the power steering fluid line. 4. Remove the reservoir from its pedestal and carefully set it aside for reuse. Note — The power steering fluid reservoir is a ROUSH CleanTech part. It is not interchangeable with the Ford part.

  • Page 52: Installing Power Steering Fluid Reservoir

    Installing Power Steering Fluid Reservoir 1. Assemble the power steering fluid reservoir on its pedestal. Note — The power steering fluid reservoir is a ROUSH CleanTech part. It is not interchangeable with the Ford part. 2. Tighten the screws to the specified torque.

  • Page 53: Fuel System Component Removal Procedures

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 3. Tighten the clamps to the specified torque. Figure 30 — Hose Clamps (1, 2 and 3), Intake Air System 4. If no additional assembly is required, open the manual shutoff valve and replace the Multivalve cover, 90-degree elbow and pressure relief hose.

  • Page 54: Removing Flow Control Solenoid

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 2. Disconnect the pressure relief hose from the 90-degree elbow in the Multivalve cover. Removing Flow Control Solenoid 1. Purge the propane from the fuel lines. Figure 32 — Flow Control Solenoid and Fuel Lines 1.

  • Page 55: Removing Fuel Lines (Under-Vehicle Toroidal Tank To Solenoid)

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Figure 33 — Intermediate Fuel Line Routing Removing Fuel Lines (Under-Vehicle Toroidal Tank to Solenoid) Note — The fuel supply and fuel return lines quick connected into the fuel tank Multivalve are serviceable only with the fuel tank removed.

  • Page 56: Removing Fuel Fill Line (Filter To Tank)

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 4. Disconnect the forward fuel return line from the fuel control solenoid. Figure 35 — Forward Fuel Return Line at Flow Control Solenoid 5. Release the forward fuel supply line from the rear of the right-side fuel rail quick connect fitting.

  • Page 57: Removing Fuel Filler Neck

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Figure 37 — Fuel Fill Line (Filter to Tank) 1. Close the manual shutoff valve on the tank. 2. Disconnect the fuel fill line at the fuel filter. 3. Arrange the line so that it can pass easily through the truck bed if removing an in-bed fuel tank or can pass over the frame rail on under-vehicle Toroidal fuel tank.

  • Page 58: Removing Fuel Filter Assembly

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Figure 39 — Fill Valve and Fuel Filler Neck Mounting Bracket 5. Remove the fill valve-to-mounting bracket nut and separate the valve from the bracket. Removing Fuel Filter Assembly Danger — A trace amount of propane fuel will be released when loosening the fittings.

  • Page 59: Removing Left (Driver's Side) Fuel Rail

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 2. Disconnect the fuel fill line from the filler neck. 3. Remove the fuel fill line. Removing Left (Driver’s Side) Fuel Rail 1. Purge the propane from the fuel lines.

  • Page 60: Removing Right (Passenger's Side) Fuel Rail

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Removing Right (Passenger’s Side) Fuel Rail 1. Purge the propane from the fuel lines. Figure 42 — Fuel Rail with Schrader Valve 2. Disconnect the PCV hose from the throttle body elbow.

  • Page 61: Removing Fuel Injector

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Removing Fuel Injector 1. Locate the fuel rail service port on the right-side fuel rail. Release the pressure in the fuel rail and lines, venting the pressure into a flare stack.

  • Page 62: Removing Injection Pressure And Temperature Sensor

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Removing Injection Pressure and Temperature Sensor 1. Purge the propane from the fuel lines. Figure 45 — Injection Pressure and Temperature Sensor 2. Disconnect the electrical connector from the Injection Pressure and Temperature Sensor (IPTS).

  • Page 63: Fuel Tank Removal Procedures

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Fuel Tank Removal Procedures Purging Fuel Tank A propane fuel tank must be empty of propane before it can be transported by a carrier. Due to the volume of fuel likely to be retained in a tank, releasing the vapor to the atmosphere would be wasteful, unsafe and an extremely slow procedure without special handling equipment.
  • Page 64 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 5. Disconnect the pressure relief hose from the outlet nozzle at the fender support rod. Figure 47 — Pressure Relief Hose Lower Connection 6. Disconnect the fuel tank electrical connector.
  • Page 65 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 11. With the help of an assistant, attach the hoist, remove the tank from the truck bed and place it on a suitable surface. Figure 49 — In-Bed Tank on Blocks Note —...

  • Page 66: Removing Under-Vehicle Toroidal Tank

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 14. Remove the shield from the tank. Figure 50 — In-Bed Fuel Tank Shield Components 1. Upper Cross 4. Lower Cross Brace Brace L Bracket 2. Fuel Line Shield (2 required) 3.
  • Page 67 Note — Some applications have a nut under the 90-degree elbow that must be removed prior to removing the cover. Caution — If the 90-degree elbow or nut and tube assembly spins and cannot be removed, STOP and contact ROUSH CleanTech Customer Service at 800-597-6874. Current as of 12-14-2010 12/14/2010...
  • Page 68 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 5. With the cover removed, locate the manual shutoff valve. Turn the manual shutoff valve clockwise until it stops. The propane supply from the tank is now shut off. Note — The manual shutoff valve can be hard to turn. From fully open to fully closed is approximately 2-1/2 turns.
  • Page 69 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 7. Disconnect the fuel tank fuel supply line from the forward fuel supply line and the fuel tank fuel return line from the fuel control solenoid. Figure 54 — Fuel Tank Fuel Supply and Fuel Return Line Connections 8.
  • Page 70 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 10. Support the fuel tank safety tub and remove the bolts securing the tube brackets to the tank brackets. 11. Remove the safety cable fasteners and cables. Figure 56 — Fuel Tank Safety Tub and Cables 12.
  • Page 71 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 14. Remove the bolts attaching the tank mounts to the frame rail brackets and the spare tire carrier bracket at the rear. Remove the mounting isolators and crush limiters as necessary.

  • Page 72: Fuel Tank Installation Procedures

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 22. Remove the fuel fill line from the fitting on the Multivalve. Figure 60 — Fuel Fill Line 23. Pull the fuel fill line through the tank collar. Fuel Tank Installation Procedures...

  • Page 73: Installing Under-Vehicle Toroidal Tank

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Installing Under-Vehicle Toroidal Tank Caution — Hand tighten all fuel line connections and fasteners before using a wrench to avoid cross threading. Failure to heed this caution can result in component damage.
  • Page 74 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 9. Arrange the fuel lines and wiring harness as shown so that the Multivalve cover can be easily installed later. Note — There is a connector with two wires for engineering diagnostics at this time.
  • Page 75 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 18. Position the safety tub under the fuel tank, install the fasteners and tighten to the specified torque. Figure 64 — Fuel Tank Safety Tub and Cables 19. Connect the fuel tank 6-pin connector to the main body harness connector. Install tie straps as necessary to secure the harness.
  • Page 76 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 20. Connect the fuel supply line to the forward fuel supply line and the fuel return line to the fuel control solenoid. Tighten the fuel line fittings to the specified torque.
  • Page 77 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Note — The manual shutoff valve can be hard to turn. From fully open to fully closed is approximately 2-1/2 turns. Figure 68 — Multivalve Assembly 1. Electrical Pass 5. Fuel Filler Inlet...

  • Page 78: Installing In-Bed Tank

    30. Start and run the engine and check for diagnostic trouble codes. Repair as necessary. Any questions, please contact ROUSH CleanTech Customer Service at 800-597-6874. Installing In-Bed Tank Note — Before installing the in-bed tank into the vehicle, provide a place for prepping the tank for installation.
  • Page 79 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 5. Connect the off-tank fuel return line to the quick connect fitting on the Multivalve. Figure 70 — Fuel Lines and Electrical Connector 6. Assemble the fuel fill line on the Multivalve and tighten the connector to the specified torque.
  • Page 80 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 9. Assemble the shield onto the fuel tank and tighten the shield fasteners to the torque specified. Figure 71 — In-Bed Fuel Tank Shield Components 1. Upper Cross 4. Lower Cross...
  • Page 81 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Warning — Keep hands clear of the cross brace between the supports as the tank approaches the bed of the truck. Failure to heed this warning can result in serious personal injury.
  • Page 82 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 16. Attach the off-tank fuel lines to the retention clips. Figure 74 — Fuel Lines 1. Fuel Return Line 2. Fuel Supply Line 17. Connect the fuel fill line to the inlet of the fuel filter and tighten to the specified torque.

  • Page 83: Fuel System Component Installation Procedures

    26. Start and run the engine and check for diagnostic trouble codes. Repair as necessary. Any questions, please contact ROUSH CleanTech Customer Service at 800-597-6874. Fuel System Component Installation Procedures Each of the following installation procedures is complete. If two or more procedures are required, they can be performed in any convenient order.

  • Page 84: Installing Injection Pressure And Temperature Sensor

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Installing Injection Pressure and Temperature Sensor 1. Install the Injection Pressure and Temperature Sensor (IPTS) into the left-side fuel rail. Figure 77 — Injection Pressure and Temperature Sensor 2. Connect the electrical connector to the IPTS.

  • Page 85: Installing Left (Driver's Side) Fuel Rail

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 1. Install and tighten the right-side fuel rail bolts to the specified torque. Figure 78 — Right-Side Fuel Rail 2. Connect the crossover fuel line to the right-side fuel rail and tighten to the specified torque.
  • Page 86 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 3. Install and tighten the fuel rail bolts to the specified torque. Figure 80 — Left-Side Fuel Rail 4. Connect the fuel return line at the rear end of the left-side fuel rail.

  • Page 87: Installing Fuel Filter Assembly

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 10. Connect the Mass Air Flow sensor electrical connector. 11. If no additional assembly is required, open the manual shutoff valve and replace the Multivalve cover, 90-degree elbow and pressure relief hose.
  • Page 88 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 1. Attach the fill valve to the fuel filler neck mounting bracket. Install the nut and tighten to the specified torque. Figure 84 — Fill Valve and Fuel Filler Neck Mounting Bracket 2.

  • Page 89: Installing Fuel Fill Line (Filler Neck To Filter)

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Installing Fuel Fill Line (Filler Neck to Filter) 1. Connect the fuel fill line to the filler neck. Figure 86 — Fuel Fill Line 2. Connect the fuel fill line to the inlet end of the fuel filter and tighten to the specified torque.

  • Page 90: Installing Fuel Lines (Solenoid To Engine)

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 3. Connect the fuel fill line securely to the outlet end of the fuel filter and tighten to the specified torque. Figure 87 — Fuel Fill Line (Filter to Tank) 4.

  • Page 91: Installing Fuel Lines (In-Bed Tank To Solenoid)

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 3. Press the tank fuel lines with sleeves into the retention clips on the frame rail. Figure 88 — Tank Fuel Line Connections Installing Fuel Lines (In-Bed Tank to Solenoid) 1.

  • Page 92: Installing Pressure Relief Hose

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement 6. Connect the battery. Installing Pressure Relief Hose 1. Connect the pressure relief hose to the 90-degree elbow in the Multivalve cover. Retain with spring clamp. 2. Connect the pressure relief hose to the outlet nozzle bracket at the fender support rod.

  • Page 93: Specifications

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement SPECIFICATIONS Engine Specifications ROUSH CleanTech Conversion Ford 5.4L LPI Engine Bore and Stroke 90.2 mm x 105.7 mm Compression Ratio 9.0:1 Displacement 5.4 Liters Engine Architecture V8 SOHC Fuel System...

  • Page 94: Fastener Torque Values

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Fastener Torque Values Fasteners Torque in N•m (Lb-Ft/Lb-In) In-Bed Under-Vehicle Description Cylindrical Tank Toroidal Tank Air Box Support Bracket Bolts 25 ±3 (18 ±2) 25 ±3 (18 ±2) Air Box Tube Clamps 4 ±0.5 (35 ±4 lb-in)
  • Page 95 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Fittings and Connections Torque in N•m (Lb-Ft/Lb-In) In-Bed Under-Vehicle Description Cylindrical Tank Toroidal Tank Forward Return Line-to-Flow Control Solenoid (blue tag) 21 ±2 (15 ±1) 21 ±2 (15 ±1) Forward Supply Line to Intermediate Supply Line except 21 ±2 (15 ±1)

  • Page 96: Schematics

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement SCHEMATICS Fuel System Flow Diagrams Fuel Flow Current as of 12-14-2010 12/14/2010...

  • Page 97: Electrical Wiring Diagram

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Electrical Wiring Diagram Wiring Schematic Current as of 12-14-2010 12/14/2010...

  • Page 98: Vehicle Harness

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Vehicle Harness Current as of 12-14-2010 12/14/2010...

  • Page 99: In-Tank Wire Harness

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement In-Tank Wire Harness Current as of 12-14-2010 12/14/2010...

  • Page 100: Tools And Equipment

    ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement TOOLS AND EQUIPMENT Special Tools Fuel Pressure Gauge Kit (0–500 psi) Safety Glasses Current as of 12-14-2010 12/14/2010...
  • Page 101 ® ROUSH CleanTech F-150 Liquid Propane Injection Service Manual Supplement Eyebolt and 5/8"-11 Locknut Gloves (Approved for Propane) Liquid Leak Detector Current as of 12-14-2010 12/14/2010...

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