Propane Refueling

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Agility Fuel Systems recommends that the Liquid Propane Injection® (LPI) vehicle be refilled with fuel at stations that are specifically designed for vehicle refueling. For assistance locating LPG fuel stations, contact Agility Fuel Systems at www.agilityfuelsystems.com or at 1-949-267-7745.

The propane fuel system utilizes a closed system, with fuel supply and return lines. This requires more advanced refueling equipment due to variances in pressure. When refueling the vehicle at a station not specifically designed for dispensing propane (also referred to as autogas), the refueling process may be very slow or the tank may not fill at all. The vehicle propane tank is subjected to heat from the pavement and chassis components, which cause a normal increase in tank pressure. The station pump may not be able to produce pressure high enough to overcome that of the tank on the vehicle. It is recommended that the filling dispenser have a minimum of 90 psi (621 kPa) pump differential boost pressure over the storage tank pressure; most modern stations are designed to 130 psi (896 kPa) differential pressure. It is recommended to refuel the vehicle at a modern station to prevent any customer inconvenience.

LPI fuel tanks are equipped with both an 80% fixed liquid level gauge, and an automatic overfill protection device (OPD). The LPI system is designed to be filled reliably and safely using only the OPD. Therefore, it is not recommended to use the 80% fixed liquid level gauge unless required by the filling station attendant, or for annual OPD verification. For instructions on how to perform the annual OPD verification test, go towww.agilityfuelsystems.com.

Propane is a liquid under pressure and is stored in a pressure vessel unlike a gasoline or diesel tank. A propane tank must never be filled to more than 80% of its actual capacity, to allow room for expansion. 80% is considered "full" for all propane tanks. When the tank is filled to the correct 80% level, the fuel gauge should read full.

The following steps describe a typical refueling procedure. See Fig. for an example of the dual propane tank system.

  1. Propane Tank

  2. Bleeder Valve

  3. Fill Valve

  4. Return Valve

  5. Access Cover and Collar

  6. Service Valve

  7. Fuel Level Gauge

  8. Propane Tank

  9. Pressure Relief Valves

Fig. 1, Dual Propane Tank System

  1. Park the vehicle on level ground to ensure that the tank is properly filled.
  2. Turn the vehicle ignition to OFF and set the parking brake. Chock the tires if required.
  3. Ensure that there are no open flames or ignition sources in the area.
  4. Open the fuel door and remove the fuel tank cap from the fuel fill valve.
  5. Inspect the fill valve O-ring, making certain the O-ring is seated in the groove and is not damaged or missing.

    6. Caution: Never connect the propane fill nozzle to the tank fill valve if the O-ring is damaged or missing, as this could result in serious injury. Replace the O-ring before connecting the propane fill nozzle.

  6. Connect the propane fill nozzle to the tank fill valve.
  7. Rotate the propane fill valve nozzle clockwise until it is firmly attached to the tank fill valve.
  8. Close the fill nozzle vent valve if so equipped.
  9. Open the 80% bleeder valve only if required. Agility Fuel Systems does not recommend using the bleeder valve. Use of the valve in a low emission fuel station is prohibited.
  10. Open the valve on the refueling nozzle.
  11. Turn the propane dispenser on to begin refueling.
  12. When the OPD stops the flow of fuel into the tank, close the filling valve.
    If use of the 80% bleeder valve is required, stop filling when liquid from the bleeder appears in the form of a white cloudy vapor.
  13. Turn the propane dispenser off.

    14. Note: Never overfill the propane fuel tank. Overfilling the fuel tank can cause a dangerous condition, resulting in serious injury and damage to the vehicle.

    After refueling, if a strong smell of propane persists or if a hissing sound is heard, notify the fuel station operator. Do not start the vehicle.

  14. Disconnect the filling nozzle from the tank fill valve.
    1. If necessary, first open the vent valve on the nozzle, if so equipped, and release the pressure from the valve for safety.
    2. Rotate the filling nozzle connector counterclockwise and remove it. Then return it to the dispenser.

    15. Note: Some vehicles are equipped with a fuel door interlock option. When the fuel door is open, the vehicle will not start.

  15. Install the fuel cap on the fuel fill valve and close the fuel door.
  16. Check for leaks on the fill valve and connecting piping, and around the 80% bleeder valve.
  17. Ensure that all of the fuel tank valves are in the fully-closed position.
Note:
Parent topic: Propane Fuel System
Document Number: 0000107434
Manual Publication Date: 2024-05-07
Topic Publication Date: 2024-05-06