Solenoid - Stuck Closed or Does Not Operate

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.

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 1: Turning In Manual Lock-Down Valve Jackscrew On Fuel Tank Solenoid Valve(s)

Courtesy of FORD MOTOR CO.

Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve(s).
Perform the fuel line venting procedure. For additional information, refer to FUEL LINE EVACUATION .
Disconnect the fuel fill line from the fuel fill valve.

Fig 2: Disconnecting Fuel Fill Line From Fuel Fill Valve
Courtesy of FORD MOTOR CO.
Connect the Fuel Venting Kit and Adapter to the fuel fill line.

Fig 3: Connecting Fuel Venting Kit And Adapter To Fuel Fill Line
Courtesy of FORD MOTOR CO.

NOTE: Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.

NOTE: All fuel tank solenoid valves must be in the locked down position.

Fig 4: Connecting Grounding Cable To Back Side Of Fuel Fill Valve

Courtesy of FORD MOTOR CO.

Connect the Grounding Cable to the back side of the fuel fill valve at the fuel line connection.
Connect the Grounding Cable to the ground rod.

Fig 5: Connecting Grounding Cable To Ground Rod
Courtesy of FORD MOTOR CO.
Connect the Fuel Filler Neck Venting Kit to the Venting Hose Assembly and Adapter.

Fig 6: Connecting Fuel Filler Neck Venting Kit
Courtesy of FORD MOTOR CO.
Connect the Fuel Venting Kit to the Fuel Filler Neck Venting Kit.

Fig 7: Connecting Fuel Venting Kit To Fuel Filler Neck Venting Kit
Courtesy of FORD MOTOR CO.
Connect the Venting Hose Assembly to the vent stack.

Fig 8: Connecting Venting Hose Assembly To Vent Stack
Courtesy of FORD MOTOR CO.
Remove the manual lockdown valve from the fuel tank solenoid valve of the fuel tank to be vented.

Fig 9: Removing Manual Lockdown Valve
Courtesy of FORD MOTOR CO.

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.

Fig 10: Installing Override Tool Into Fuel Tank Solenoid Valve

Courtesy of FORD MOTOR CO.

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

Fig 11: Turning In Override Tool Jackscrew
Courtesy of FORD MOTOR CO.
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.
Vent the fuel tank until the fuel flow stops.
Remove the override tool from the fuel tank solenoid valve.

Fig 12: Removing Override Tool From Fuel Tank Solenoid Valve
Courtesy of FORD MOTOR CO.
Install the fuel tank solenoid manual lock-down valve.

Fig 13: Installing Fuel Tank Solenoid Manual Lock-Down Valve
Courtesy of FORD MOTOR CO.
Turn in the manual lock-down valve jackscrew on the fuel tank solenoid valve.

Fig 14: Turning In Manual Lock-Down Valve Jackscrew On Fuel Tank Solenoid Valve
Courtesy of FORD MOTOR CO.
Repeat the procedure until all affected tanks are vented.
Install the fuel fill line onto the fuel fill valve.

Fig 15: Installing Fuel Fill Line Onto Fuel Fill Valve
Courtesy of FORD MOTOR CO.