Removal & Installation (Extended Range)

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.

NOTE: Vent system and tank pressure. See FUEL SYSTEM PRESSURE RELEASE . If removing fuel tank for replacement of lines or support straps, turn manual lockdown valve jackscrew inward on fuel tank solenoid valve. Lockdown valve jackscrew on extended range fuel tank is accessed through an access hole in vapor retaining cover. Fuel tank assembly may be referred to as midship fuel tank assembly.

NOTE: Loosen fuel line fittings slowly to allow any excess line pressure to vent through fitting connection.

Disconnect negative battery cable. Raise and support vehicle. Disconnect electrical connectors from fuel tank shutoff solenoid valve. Loosen fuel line fitting and disconnect upper fuel line and flexible tube retainer. Remove 2 nuts retaining fuel lines and wiring harness and position them into luggage compartment. Lower vehicle.
Remove rear seat. Remove bolts and nuts retaining partition separator. Remove 8 bolts retaining frame to fuel tank mounts and remove frame and shield assembly. Remove 2 bolts retaining straps to fuel tank mounts. Remove 4 bolts retaining fuel tank to mounts and remove fuel tank straps. Install lifting equipment and remove extended range fuel tank.

NOTE: Replace fuel line "O" rings. Lubricate "O" rings with 5W-30 engine oil. DO NOT use a silicone lubricant.

To install, reverse removal procedure. After installation is complete, LPG fuel lines must be leak tested. Perform COMPRESSED NATURAL GAS LEAK TEST under FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - EEC-V - NGV article.