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Compressed Natural Gas Fuel Tank Evacuating

WARNING: This page is about a different car, the 2002 Ford Econoline and 2002 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: The natural gas fuel system is always pressurized to 95 psi (655 kPa) downstream of the fuel pressure regulator and up to 3600 psi (24,821 kPa) upstream of the fuel pressure regulator. Use care when servicing the fuel system or personal injury can occur. The fuel system pressure must be relieved before any component can be removed. The fuel tanks must be evacuated prior to tank removal. Removal of components without pressure relief or tank evacuation can cause natural gas to escape into the air and cause injury or death.
NOTE: Natural Gas Vehicle (NGV) Pressure Test and Vent Kit (134-00116) or equivalent test equipment are necessary to perform the following fuel tank evacuating procedures. Natural gas vehicle pressure test and vent kit consists of Rotunda Fuel Filler Neck Venting Kit (134-00117), Venting Hose (134-00118) and Grounding Cable (134-00121). All fuel tank solenoid valves must be in the locked down position.
  1. Connect Grounding Cable (134-00121) to back side of the fuel fill valve at the fuel line connection. See Fig 1. Connect grounding cable to ground rod. Turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve(s). See Fig 2. Connect Fuel Filler Neck Venting Kit (134-00117) to the fuel filler valve. See Fig 3. Connect Venting Hose (134-00118) to the fuel filler neck venting kit. Connect the venting hose assembly to an approved vent stack.
  2. Remove fuel pump relay from battery junction box, located in engine compartment. Connect an 18 gauge jumper wire between fuel pump relay cavity terminals No. 30 and 87. Slowly open manual lockdown valve jackscrew on fuel tank solenoid valve of the fuel tank to be vented.
  3. Slowly open manual backflow valve on fuel filler valve. Observe gauge pressure of fuel filler neck venting kit. If pressure is zero psi (zero kg/cm2 ), go to next step. If pressure is at tank pressure, go to step  5.
    4. WARNING: Ensure Manual Override Tool (134-00050) jackscrew is fully retracted before installing on fuel tank solenoid valve to prevent uncontrolled gas venting.

  4. Stuck Closed Or Inoperative
    Remove fuel tank solenoid manual lockdown valve. Install Manual Override Tool (134-00050) into fuel tank solenoid of the tank being vented. Turn manual override tool jackscrew inward until fuel begins venting. Slowly open manual backflow valve on fuel filler valve and observe gauge pressure of filler neck venting kit. Pressure reading should be tank pressure. Open bleed valve on the fuel filler neck venting kit slowly and allow contents of fuel tank to vent through vent stack. Venting fuel tank may take more than an hour. Close bleed valve on fuel filler neck venting kit, and observe gauge pressure. Pressure should be about zero psi (zero kg/cm2 ). Close the manual backflow valve on fuel filler valve when fuel tank contents have been vented. Perform COMPRESSED NATURAL GAS FUEL LINE VENTING . Repeat this procedure until all affected tanks are vented.

  5. Functioning Normally Or Stuck Open

    Slowly open manual lockdown valve jackscrew on fuel tank solenoid valve of the fuel tank to be vented. Slowly open manual backflow valve on fuel filler valve. Observe gauge pressure of fuel filler neck venting kit. Pressure should be at tank pressure. Open bleed valve on the fuel filler neck venting kit slowly and allow contents of fuel tank to vent through vent stack.
  6. Venting fuel tank may take more than an hour. Close bleed valve on fuel filler neck venting kit, and observe gauge pressure. Pressure should be about zero psi (zero kg/cm2 ). Remove fuel tank solenoid manual lockdown valve.
    7. WARNING: Ensure Manual Override Tool (134-00050) jackscrew is fully retracted before installing on fuel tank solenoid valve to prevent uncontrolled gas venting.
  7. Install Manual Override Tool (134-00050) into fuel tank solenoid of the tank being vented. Slowly turn manual override tool jackscrew inward until fuel begins venting. Vent the fuel tank until the fuel flow through vent stack stops. Close the manual backflow valve on fuel filler valve when fuel tank contents have been vented. Perform COMPRESSED NATURAL GAS FUEL LINE VENTING . Repeat this procedure until all affected tanks are vented.
Fig 1: Connecting Grounding Cable To Backside Of Fuel Fill Valve
G99J02862Courtesy of FORD MOTOR CO.
Fig 2: Identifying Fuel Tank Solenoid Components
G98E00343Courtesy of FORD MOTOR CO.
Fig 3: Connecting Fuel Filler Neck Venting Kit-To-Fuel Fill Valve
G99C02868Courtesy of FORD MOTOR CO.
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