Fuel Tank Evacuation

FUEL TANK EVACUATION

Special Tool(s):

SPECIAL TOOL(S)

WARNING:
- The fuel supply lines will remain pressurized after engine shutdown. When servicing fuel-related components, do not smoke or carry lighted tobacco or any open flame of any type. Flammable gases may be present and ignite, resulting in possible personal injury.
- Do not modify the system configuration or components, or install components with parts not specially designed for use with natural gas. Ford Motor Company has specially designed the materials, components and system configuration for the 5.4L natural gas vehicles, and each particular system is precisely calibrated for efficient operation. The use of different parts or materials can produce an untested configuration that could result in fire or personal injury, or cause engine damage.
- Fuel line venting is required prior to fuel system component service.
- Eye and ear protection are required to be worn during venting, or removal and installation, of fuel system components.
- The status (stuck open, stuck closed, does not operate or good) of each fuel tank solenoid valve must be identified prior to venting the fuel tanks.

NOTE:
- It is recommended that venting be performed with a vent stack. A typical vent stack installation is shown in the Description and Operation. This is a typical installation only. Any vent stack installation must be approved by local authorities.
- Do not vent any fuel tank unless a new fuel tank or a new fuel tank solenoid valve is installed. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.

1. The following procedures are required to be used when venting fuel from the fuel tanks in order to remove fuel tanks.

Solenoid - Functions Normally

1. NOTE: On vehicles equipped with an extended range fuel tank, the jackscrew can be reached through an access hole in the vapor retaining cover.

Turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve(s).

2. Perform the fuel line venting procedure.

3. Disconnect the fuel fill line from the fuel fill valve.

4. Connect the Fuel Venting Kit and Adapter to the fuel fill line.

5. NOTE:
- Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
- All fuel tank solenoid valves must be in the locked down position.

Connect the Grounding Cable to the fuel fill line connection.

6. Connect the Grounding Cable to the ground rod.

7. Connect the Fuel Filler Neck Venting Kit to the Venting Hose Assembly and Adapter.

8. Connect the Fuel Venting Kit to the Fuel Filler Neck Venting Kit.

9. Connect the Venting Hose Assembly to the vent stack.
10. Remove the fuel pump relay from the power distribution box.
11. Construct a jumper wire from 152 mm (6 inches) of 18 gauge wire and two spade terminal ends.

12. Jumper the fuel pump relay circuit from Socket 87 to Socket 30.
13. Slowly open the manual lockdown valve jackscrew on the fuel tank solenoid valve of the fuel tank to be vented.
14. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as, "functions normally".
15. Slowly open the bleed valve on the venting kit and allow the contents of the fuel tank to vent to the atmosphere. Venting can take in excess of one hour.
16. Close the bleed valve on the venting kit, and observe the gauge pressure. The pressure should be at or near 0 kPa (0 psi).
17. Repeat the procedure until all affected tanks are vented.

18. Install the fuel fill line onto the fuel fill valve.

Solenoid - Stuck Open

3. Disconnect the fuel fill line from the fuel fill valve.

4. Connect the Fuel Venting Kit and Adapter to the fuel fill line.

6. Connect the Grounding Cable to the ground rod.

7. Connect the Fuel Filler Neck Venting Kit to the Venting Hose Assembly and Adapter.

8. Connect the Fuel Venting Kit to the Fuel Filler Neck Venting Kit.

9. Connect the Venting Hose Assembly to the vent stack.
10. Slowly open the manual lockdown valve jackscrew on the fuel tank solenoid valve of the fuel tank to be vented.
11. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure should be at tank pressure if the fuel tank solenoid valve was identified as, "stuck open".
12. Slowly open the bleed valve on the venting kit and allow the contents of the fuel tank to vent to the atmosphere. Venting can take in excess of one hour.
13. Close the bleed valve on the venting kit, and observe the gauge pressure. The pressure should be at or near 0 kPa (0 psi).

14. Remove the fuel tank solenoid manual lockdown valve.

15. WARNING: Make sure the jackscrew in the Manual Override Tool is retracted fully (counterclockwise) prior to installation into the fuel tank solenoid valve. Installation of the override tool in the venting position will cause natural gas to be immediately released.

Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.

16. Turn in the override tool jackscrew until fuel flows.
17. Vent the fuel tank until the fuel flow stops.

18. Remove the override tool from the fuel tank solenoid valve.

19. Install the fuel tank solenoid manual lockdown valve.

20. Turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve.
21. Repeat the procedure until all affected tanks are vented.

22. Install the fuel fill line onto the fuel fill valve.

Solenoid - Stuck Closed or Does Not Operate

3. Disconnect the fuel fill line from the fuel fill valve.

4. Connect the Fuel Venting Kit and Adapter to the fuel fill line.

6. Connect the Grounding Cable to the ground rod.

7. Connect the Fuel Filler Neck Venting Kit to the Venting Hose Assembly and Adapter.

8. Connect the Fuel Venting Kit to the Fuel Filler Neck Venting Kit.

9. Connect the Venting Hose Assembly to the vent stack.

10. Remove the manual lockdown valve from the fuel tank solenoid valve of the fuel tank to be vented.

11. WARNING: Make sure that the jackscrew in the Manual Override Tool is retracted fully (counterclockwise) prior to installation into the fuel tank solenoid valve. Installation of the override tool in the venting position will cause natural gas to be immediately released.

CAUTION: Once the fuel tank solenoid valve has been opened using the override tool, a new fuel tank solenoid valve must be installed.

Install the override tool into the fuel tank solenoid valve of the tank to be vented.

12. Slowly turn in the override tool jackscrew until fuel flows. Observe the gauge pressure of the Fuel Filler Neck Venting Kit. The pressure reading should be at tank pressure.
13. Slowly open the bleed valve on the venting kit and allow the contents of the fuel tank to vent to the atmosphere. Venting can take in excess of one hour.
14. Vent the fuel tank until the fuel flow stops.

15. Remove the override tool from the fuel tank solenoid valve.

16. Install the fuel tank solenoid manual lockdown valve.

17. Turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve.
18. Repeat the procedure until all affected tanks are vented.

19. Install the fuel fill line onto the fuel fill valve.