Fuel Tank Assembly
The ROUSH Clean Tech LPG system, as planned on the E-450 cutaway vehicle, will utilize a dual manifold tank and occupies the same vehicle package envelop as the OEM gasoline tank that it replaces. The tanks are manufactured from ductile steel and individually certified to ASME standards. Refer to Figures 3 & 4.
Figure 3: E-450 Fuel Tank Assembly
Figure 4: E-450 Fuel Tank Assembly as installed in vehicle frame
In order to transfer the LPG fuel from the tank to the engine, the fuel tank assembly contains a dual fuel pump assembly. Each fuel pump in the assembly is controlled by an electronic fuel pump relay which is powered by the Powertrain Control Module, PCM, as it would in the OEM gasoline vehicle application.
A total of four fuel filters are used with the fuel tank assembly. One filter is located external to the tank and is contained within the fuel fill line between the tank and fill valve. Three additional filters are located inside of the tank, one at the fuel pump assembly inlet and one at the outlet of each fuel pump.
The tank contains a fuel level sender that sends a signal to an electronic module that is designed to match the output profile of the OEM fuel level sender. Internal tank baffles and a jet pump are used to maximize fuel pickup and delivery during low fuel conditions and extreme vehicle dynamic maneuvers.
Tank Safety Features
The OEM vehicle inertia switch is retained as a means to disable fuel pump operation in the event of a collision. Additional safety features contained within the tank assembly itself include a mechanical 80% Overfill Prevention Device (OPD) to eliminate the potential for over filling the tank. A pressure relief valve will vent the tank in the event that tank pressure exceeds 312 psig. An excess flow valve is located within the supply line and is used to detect when an inordinate amount of fuel is being supplied to the system and will immediately stop the flow of fuel. In the event that a line ruptures, these valves prevent the dispersing of fuel directly into the atmosphere.
Figure 5: E-450 Fuel Tank Assembly Internal View