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Fuel Tank Evacuation: Notes

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tool(s)
G02765999Courtesy of FORD MOTOR CO.
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.
WARNING: 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.
WARNING: Fuel line venting is required prior to fuel system component service.
WARNING: Eye and ear protection are required to be worn during venting, or removal and installation, of fuel system components.
WARNING: 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 DESCRIPTION AND OPERATION . This is a typical installation only. Any vent stack installation must be approved by local authorities.
NOTE: 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.

    2. SOLENOID - FUNCTIONS NORMALLY 

    NOTE: On vehicles equipped with an extended range fuel tank, the jackscrew can be reached through an access hole in the vapor retaining cover.
    Fig 2: Turning In Manual Lock-Down Valve Jackscrew On Fuel Tank Solenoid Valve(s)
    G02766000Courtesy of FORD MOTOR CO.
  2. Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve(s).
  3. Perform the fuel line venting procedure. For additional information, refer to FUEL LINE EVACUATION .
  4. Connect the Grounding Cable to the ground rod.
    Fig 3: Connecting Grounding Cable To Ground Rod
    G02766001Courtesy of FORD MOTOR CO.
  5. Connect the Fuel Filler Neck Venting Kit to the Venting Hose Assembly and Adapter.
    Fig 4: Connecting Fuel Filler Neck Venting Kit
    G02766002Courtesy of FORD MOTOR CO.
  6. Connect the Venting Hose Assembly to the vent stack.
    Fig 5: Connecting Venting Hose Assembly To Vent Stack
    G02766003Courtesy of FORD MOTOR CO.
  7. Remove the fuel pump relay from the power distribution box.
  8. Construct a jumper wire from 152 mm (6 inches) of 18 gauge wire and two spade terminal ends.
  9. Jumper the fuel pump relay circuit from Socket 87 to Socket 30.
    Fig 6: Constructing A Jumper Wire
    G02766004Courtesy of FORD MOTOR CO.
  10. Slowly open the manual lock-down 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, "functions normally".
  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. Repeat the procedure until all affected tanks are vented.
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