Field Repair Instructions

FRI.0002 Ver 2.0

January 24, 2023

UPS Ford F-59 CNG Project 3 Defueling Procedure
UPS Job # 20-26 P80 / # 20-27 P100 / Job # 20-28 P120

Affected Vehicles

QTY: 800 MY2019 Ford F-59 CNG package vans
 UPS Job # 20-26 P80 / UPS Job # 20-27 P100 / UPS Job # 20-28 P120
 UPS Package Car Ranges: 170855 – 170984
199419 – 199768
834055 – 834162
834579 – 834790

Introduction
Hexagon® Agility®, has established this service procedure for defueling certain UPS Ford F-59 CNG package
vans (refer to “Affected Vehicles” section above for details).
Before proceeding further, please inspect the HP fuel filter (located on the
driver side chassis frame rail) for the presence of a bleed valve in the filter
bowl. FIGURE I–1
HP filter fuel bowl,
OBSOLETE



HP filter fuel bowl;
current specification

bleed valve assembly;
current specification

HP filter drain plug,
OBSOLETE

FIGURE I–1. LEFT: HP fuel filter bowl (OBSOLETE), drain plug (OBSOLETE)
RIGHT: HP filter bowl (CURRENT SPEC), bleed valve assembly (CURRENT SPEC)

HP filter bowl and bleed valve retrofit must be completed prior to using this
procedure. Refer to FSB.0003.

FRI.0002 Ver 2.0
January 24, 2023

UPS Ford F-59 CNG Project 3 Defueling Procedure
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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Warning and Signal Words Used in this Bulletin
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
NOTICE is used to address practices not related to physical injury, such as best
practices or tips to help an operation or procedure go smoothly and prevent
equipment damage.
CRITICAL CHARACTERISTIC – Product feature directly affects:
 Safety of vehicle users, people nearby and maintenance personnel, or
 Regulatory compliance.
MANUFACTURING CHARACTERISTIC –
 A product feature solely used to improve manufacturability or maintain process
control.
 A process parameter or step that has a significant effect on achieving a Critical
Characteristic or Significant Characteristic, or maintaining material identification/
traceability.

Required Tools and Materials
Item

Purpose

safety glasses

eye protection

5/8-in wrench (QTY:2)

remove and replace defuel kit fitting

5/8-in wrench crowfoot wrench

use with torque wrench to tighten defuel kit fitting

7/16-in wrench

tighten bleed valve pressure relief nut

11/16-in wrench

remove and replace bleed valve

11/16-in crowfoot wrench

use with torque wrench to tighten bleed valve

torque wrench

accurately tighten fuel system fittings and components

defueling service kit, CNG – Hexagon® Agility® p/n 69500019

adaptor to defuel hose, ground cable, solenoid purge harness

35-ft defueling hose – Hexagon® Agility® p/n 20100021*

remove CNG from fuel system

Swagelok® Snoop® leak detection fluid

perform leak test

Torque Seal (any color but yellow)

indicate fittings are tightened to specifications

shop rags

clean fuel system components before and after repair

O-ring lubricant

lubricate O-rings for proper seating, seal, and protection

*Required if a hose is not present at defuel vent stack.

FRI.0002 Ver 2.0
January 24, 2023

UPS Ford F-59 CNG Project 3 Defueling Procedure
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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Fuel System Schematic
Item

Description

1

fuel fill panel

2

driver side (DS) cylinder

3

passenger side (PS) cylinder

4

1/4-turn manual shutoff valve

5

driver side (DS) cylinder manual valve

6

passenger side (PS) cylinder manual valve

7

HP fuel filter

8

bleed valve

9

HP fuel gauge

6
3

8
7

4

2
5
1

FRONT

FRI.0002 Ver 2.0
January 24, 2023

UPS Ford F-59 CNG Project 3 Defueling Procedure
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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3 of 22

Defueling Diagram
vent stack/pipe

– properly supported,
minimum 10-ft (3 m) above fuel vessel

(vehicle)

To rest of fuel
system

NGV
valve

defuel
adaptor hose
fitting

HP
filter

defuel
adaptor hose
receptacle

defuel
adaptor
hose

ground cable clip

bracket
defuel hose

– electrically
conductive, flexible

defuel hose
connector

defuel hose
nozzle

grounding rod

ground
cable

support
structure
or building
wall

– minimum 8-ft
(2.44 m) deep

manual
valve

ground cable clips

Defueling Special Tools
Item

Part Number

Description

A

69500019

Kit, defueling

B

(POA A)

Supply solenoid valve (SSV) jumper cable – NOTE: not used for this procedure

C

(POA A)

Ground cable

D

(POA A)

Defuel adaptor hose

E

20100021

Defueling hose, 35-ft
E

A
B
D

C
POA = part of assembly/kit; item not available separately
FRI.0002 Ver 2.0
January 24, 2023

UPS Ford F-59 CNG Project 3 Defueling Procedure
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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1. Vehicle Preparation
Set emergency brake and place wheel chocks under vehicle tires.
Wear approved personal protective equipment (PPE) including safety glasses.
Before servicing fuel system plumbing and components, fuel pressure must be
released using a depressurization procedure.

2. Depressurization Procedure
Depressurization and defueling must be performed in well-ventilated area.
Vehicle will be immobile after depressurization; plan accordingly.
1. CLOSE driver side (DS) cylinder manual valve (5). FIGURE 2–1

FRONT

4

6

5

FIGURE 2–1. (5) DS manual cylinder valve, (6) PS manual cylinder valve, (4) 1/4-turn manual shutoff valve

2.
3.
4.
5.

CLOSE passenger side manual valve (6). FIGURE 2–1
OPEN 1/4-turn manual shutoff valve (4). FIGURE 2–1
Start engine and idle until engine stalls.
Attempt to start engine again.
a. If engine starts, allow engine to idle until it stalls.
b. Repeat Step 5 until engine fails to start.

FRI.0002 Ver 2.0
January 24, 2023

UPS Ford F-59 CNG Project 3 Defueling Procedure
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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6. Remove bleed valve pressure relief port cap and pressure relief nut cap from bleed valve (8) located on HP
fuel filter (7). FIGURE 2–2
Store caps in a clean, dry plastic
bag for reinstallation later.

7

pressure relief port cap
8

pressure relief nut cap
FIGURE 2–2. (7) HP fuel filter, (8) bleed valve, pressure relief port cap, pressure relief nut cap

7. Use a 7/16-in wrench to loosen pressure relief nut on the bleed valve (8). FIGURE 2–3
High pressure fuel and condensation will exit from pressure relief port; wear
appropriate PPE and maintain safe distance.
Listen for the flow of escaping fuel to stop to verify pressure has been fully
released.

FRONT
pressure
relief port
7

high pressure fuel escaping

pressure
relief nut

8

FIGURE 2–3. (7) HP fuel filter, (8) bleed valve, pressure relief nut, pressure relief port

8. CLOSE bleed valve (8).
9. CLOSE 1/4-turn manual shutoff valve (4).

FRI.0002 Ver 2.0
January 24, 2023

UPS Ford F-59 CNG Project 3 Defueling Procedure
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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3. Defueling Procedure
Verify (9) HP fuel gauge on (1) fuel fill panel reads approximately zero before
proceeding. FIGURE 3–1
9

FRONT

1
FIGURE 3–1. (1) fuel fill panel, (9) HP fuel gauge

1. Verify (5) driver side (DS) cylinder manual valve and (6) passenger side (PS) cylinder manual valve are
CLOSED. NOTE: Cylinder shields not shown. FIGURE 3–2
FRONT

4
6
5
FIGURE 3–2. (4) 1/4-turn manual shutoff valve, (5) DS cylinder manual valve, (6) PS cylinder manual valve

2. Verify (4) 1/4-turn manual shutoff valve is CLOSED. FIGURE 3–2
3. Use an 11/16-in wrench to remove bleed valve (8) from (7) HP fuel filter. FIGURE 2–5
7

FRONT

8

Store (8) bleed valve in a clean, dry plastic bag for
reinstallation later.

FIGURE 3–5. (7) HP fuel filter, (8) bleed valve
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January 24, 2023

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PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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4. Select defuel hose adaptor from defueling service kit, CNG – Hexagon® Agility® p/n 69500019. FIGURE 2–6
Inspect defuel hose adaptor NGV connector O-ring (not visible) for damage;
replace if necessary.

NGV valve

NOTE: Defuel hose
adaptor shown
shortened for clarity.
Verify defuel hose adaptor NGV valve is CLOSED.
FIGURE 3–6. Defuel hose adaptor components

5. Remove fitting from defuel hose adaptor using a pair of 11/16-in wrenches. FIGURE 3–6
Verify fitting O-ring and sealing surfaces are clean and free of debris.
Apply a light coat of O-ring lubricant to fitting O-ring before installing in HP fuel filter bowl port.
6. Install fitting in (7) HP fuel filter bowl port (circled) using a 5/8-in socket or crows foot wrench. FIGURE 3–7
FRONT

7

fitting
Torque fitting to 25 ft-lbs (33.9 Nm).
FIGURE 3–7. (7) HP fuel filter, filter bowl drain port (red oval), fitting

FRI.0002 Ver 2.0
January 24, 2023

UPS Ford F-59 CNG Project 3 Defueling Procedure
PRINTED AND DOWNLOADED COPIES ARE NOT CONTROLLED

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7. Attach defuel hose adaptor end to fitting using a 5/16-in wrench and a 11/16-in wrench. FIGURE 3–8
FRONT
7

defuel hose adaptor end

fitting
Tighten hose fittings according to Appendix A: WI.0199 Removal and Retightening of Tube
Fittings.
FIGURE 3–8. (7) HP fuel filter with fitting and defuel hose adaptor attached

8. Attach fuel facility ground cable clips to the following locations: (a) known good vehicle ground, (b) vent stack
ground, and, if present, connect (c) third ground cable clip to a dedicated ground rod. FIGURE 2–9
Always ground vehicle and vent stack when defueling.
If fuel facility ground cable is not present, use ground cable from Hexagon®
®
Agility defueling service kit, CNG, p/n 69500019.
Always follow federal, state, local, and fuel facility rules and guidelines.
(vehicle)
vent stack/pipe

– properly supported,
minimum 10-ft (3 m) above ground
To rest of fuel
system

HP
filter

defuel
adaptor
hose

a

ground cable clip

b

c

ground
cable

grounding rod
– minimum 8-ft
(2.44 m) deep

ground cable clips