SVE BULLETIN - Ford Fleet

SVE BULLETIN
SPECIAL VEHICLE ENGINEERING – BODY BUILDERS ADVISORY SERVICE
Toll-free: (877) 840-4338 E-Mail: bbasqa@ford.com (preferred)
Fax: (313) 594-2633 Website: www.fleet.ford.com/truckbbas
Q-96 R2 Date: May 9, 2003
Revised: Oct. 20, 2003
New LEV-II Evaporative Emissions Standards
Note: This bulletin is being revised (again) to update the contact information at TI Automotive – See page 2
To: All Modifiers of Ford Motor Truck Chassis
Models Affected: All 2004 E-Series and 2005 F-Series
Action Requested/Background
Please provide a copy of this bulletin to all personnel associated with codes and standards, including purchasing,
engineering, quality, manufacturing, and legal. LEV-II standards mandates 100% of motor vehicles achieve compliance
by the 2006 model year, with lesser percentage of compliance required in 2004 and 2005. Ford Motor is phasing-in the
changes summarized below in stages with the E-Series vehicles leading in model year 2004 (Job #1 9/15/2003) and the
F-Series in 2005. Any modifications to a LEV-II fuel system will require the modifier to certify compliance with LEV-II
Emission Standards.
Description
LEV-II Fuel System Requirements
LEV-II (Low Emission Vehicle II Program) is based upon the California Air Resources Board (CARB) requirements,
which recently changed the hydrocarbon emissions standard for gasoline engine vehicles.
Changed From: 2.0 grams/24 hours for 15 years or 150,000 miles
Changed To: 1.0 gram/24 hours for 15 years or 150,000 miles
Per the "Texas Mandate" (USA/M/5061) Ford installs the same evaporative emission control system hardware on motor
vehicles delivered for sale in Federal states as vehicles delivered for sale in California.
MAJOR Changes to Fuel Systems to meet LEV-II Requirements
• Return fuel system eliminated. No return fuel to the fuel tank.
• Quick connects with O-Ring are used in place of all vapor push-on joints
• Vapor generation and permeation reduced with Electronic Returnless Fuel System (ERFS)
• Larger volume canister design with bleed on the vent side. The carbon canister is relocated on Cutaways.
• Upgraded material for all lines and hoses (fuel, vapor, fill)
• Upgraded corrosion resistance for 15 year/150,000 miles
• Dedicated purge lines from Vapor Management Valve (VMV) to canister
• All components are helium leak checked prior to shipment
• All components used in the fuel system are capable of meeting the virtual leak specification using helium
• The Transit Tank option is no longer available
• Fuel tank drain plug has been eliminated
• Fuel filler neck is revised to reduce vapor emissions during fuel fill
o Vans/Wagons - Fill neck vent line reduced in size and utilizes quick connect fittings. The revised vent
line runs from the filler neck to a port on the fuel pump/sending unit. A welded in place metal insert
replaces the plastic insert used in 2003.
o Cutaways/Stripped Chassis will use a configuration similar to 2003 with a new cap and metal retainer.
Originator: Stephen I. Dains/sdains Page 1 of 2 Date Issued: May 9, 2003
Q-96 R2 - LEV-II.rtf Date Revised: 10/21/2003

DURABILITY of Evaporative System
Ford will be required to honor the CARB regulations of 15-year/150,000 mile LEV-II emission requirements in California,
and also in “Section 177” states that have adopted California’s regulations as allowed by Clean Air Act (CAA). The fuel
system will be required to remain functional for at least 15 years/150,000 miles. This includes integrity against liquid or
vapor leak, no increase in permeation above the normal, stabilized level, and no increase in breathing losses from the
canister or air induction system.
TESTING
Ford automotive designs are validated for extended time by certain tests that accelerate the various wear and
deterioration phenomena. These tests are conducted at several levels:
1. Vehicle – Certified to Government requirements
2. System – Fuel permeation rig test (20-40 week tests to ensure system has reached stabilization)
3. Subsystem – Supplier tests mating components to ensure no HC permeates through interfaces.
4. Components – 100% leak check
5. Materials – All fuel related material is tested to ensure compliance with LEV-II requirements
6. Mating Surfaces – Dimensional tolerances are designed so the component/subassembly will pass the Virtual
Leak Detection (VLD) specifications as long as it is within tolerance. Where the two mating surfaces are
"owned" by different suppliers, both suppliers are required to independently verify the connection passes VLD
requirements through the tolerance range, over the CARB temperature profile.
7. Leak Testing - All assemblies 100% helium leak checked before delivery to Ford’s final assembly plant
Body Builder Recommendations:
Fuel Fill Modifications
The E-Series Cutaway/Stripped Chassis will continue to provide extended length of fuel filler hose and vent line.
Builders using Ford provided materials and installation recommendations can assume LEV-II compliance. Any non-Ford
components will require the modifier to certify compliance with LEV-II emission standards.
Fuel Lines/Vent Lines
All fuel/vent lines should be OE quality and utilize double O-ring connectors. Fuel lines should meet OE permeability
specifications.
Carbon Canister Relocation
Carbon Canister and fuel tank vent lines are part of the LEV-II fuel system. The final stage manufacturer is responsible
to certify any modification made to the fuel system for LEV-II compliance.
LEV-II Supplier Contacts/Web Addresses
The following companies can provide products or services to assist builders that modify fuel system components.
Fuel Filler Neck Fuel Line/Vapor Line Extensions Fuel System/Component Testing
Shelby Enterprises, Inc. TI Automotive TSG Testing Services Group
Jennifer Dedenbach George Manolias Doug Hughes
596-752-4552, Ext 234 586-755-8313 810-245-1600
www.shelbyenterprises.com gmanolias@us.tiauto.com www.tsglabs.com
Note: All QVM Bulletins, Ford Truck Quality Program Guidelines, Body Builders Layout Book, Incomplete Vehicle
Manual (IVM) and other builder data is available at www.fleet.ford.com/truckbbas. Since the California Air Resources
Board is the source of the LEV-II regulations, questions concerning compliance should be addressed to them. Their
web address is www.arb.ca.gov.
Sincerely,
D. J. Snyder
Modified Vehicle Engineering Quality Programs
Originator: Stephen I. Dains/sdains Page 2 of 2 Date Issued: May 9, 2003
Q-96 R2 - LEV-II.rtf Date Revised: 10/21/2003