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Fuel Tank Evacuation

WARNING: This page is about a different car, the 2002 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Fuel supply lines remain pressurized after engine shutdown. Ensure no open flame of any type is present. Flammable gases may be present and ignite, resulting in possible injury. Always release (vent) fuel pressure before disconnecting any fuel injection-related component downstream of fuel tank shutoff solenoids. DO NOT vent fuel system indoors.
CAUTION: All fuel tank solenoid valves must be tested to determine if they are functioning correctly prior to fuel tank evacuation. See SYSTEM & COMPONENT TESTING - EEC-V - NGV article in ENGINE PERFORMANCE for solenoid testing procedure.
NOTE: To perform fuel system pressure release, use Fuel Filler Neck Venting Kit (134-00117), Grounding Cable (134-00121), Manual Override Tool (134-00050), Fuel Venting Hose (164-R0911), Adapter (134-00255) and Venting Hose (134-00118). Manufacturer recommends venting fuel through a vent stack that allows natural gas to be vented outside of repair shop. Vent stack must be approved by local authorities.
NOTE: Do not vent any fuel tank unless it or the fuel tank solenoid valve is being replaced. Venting good tanks when not necessary could cause damage to fuel tank solenoid valves. This procedure should only be used when replacing tanks or fuel tank solenoid valves.
  1. Turn manual lock-down valve jackscrew on each fuel tank solenoid valve. See Figure. Perform fuel line venting procedure. See FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING) . Disconnect fuel fill line from fuel fill valve and connect to Fuel Venting Hose (164-R0911) and Adapter (134-0255). Connect grounding cable between grounding spike and fuel fill valve. See Fig 1.
  2. Connect Fuel Filler Neck Venting Kit (134-00117) to Adapter (134-0255). Connect Venting Hose (134-00118) to Fuel Filler Neck Venting Kit (134-00117) and connect to vent stack.
  3. Remove fuel pump relay from Battery Junction Box (BJB). Construct a jumper wire approximately 6" long with spade terminals on each end. Jump fuel pump relay connector terminals. See Figure.
  4. Slowly open manual lock-down valve jackscrew on fuel tank solenoid 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  6.
    5. WARNING: Ensure Manual Override Tool (134-00050) jackscrew is fully retracted before installing on fuel tank solenoid valve to prevent uncontrolled gas venting.

  5. Stuck Closed Or Inoperative
    Perform FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING) . 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. 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. Repeat this procedure until all affected tanks are vented.

  6. Functioning Normally Or Stuck Open

    Perform FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING) . Slowly open manual lockdown valve jackscrew on fuel tank solenoid valve of the fuel tank to be vented. 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.
  7. 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.
    8. WARNING: Ensure Manual Override Tool (134-00050) jackscrew is fully retracted before installing on fuel tank solenoid valve to prevent uncontrolled gas venting.
  8. 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. 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.
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