Solenoid - Stuck Open

WARNING: This page is about a different car, the 2003 Ford Econoline and 2003 Ford E450 Super Duty. 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 Manual Lockdown Valve Jackscrew

Courtesy of FORD MOTOR CO.

Turn in the manual lockdown 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 Fuel Fill Line Connection

Courtesy of FORD MOTOR CO.

Connect the Grounding Cable to the fuel fill 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 To Venting Hose Assembly And Adapter
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.
Slowly open the manual lockdown valve jackscrew on the fuel tank solenoid valve of the fuel tank to be vented.
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, "stuck open".
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.
Close the bleed valve on the venting kit, and observe the gauge pressure. The pressure should be at or near 0 kPa (0 psi).
Remove the fuel tank solenoid manual lockdown valve.

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

WARNING: Make sure 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.

Fig 10: Installing Manual Override Tool Into Fuel Tank

Courtesy of FORD MOTOR CO.

Install the Manual Override Tool into the fuel tank solenoid of the tank to be vented.
Turn in the override tool jackscrew until fuel flows.

Fig 11: Turning Override Tool Jackscrew Until Fuel Flows
Courtesy of FORD MOTOR CO.
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 lockdown valve.

Fig 13: Installing Fuel Tank Solenoid Manual Lockdown Valve
Courtesy of FORD MOTOR CO.
Turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve.

Fig 14: Turning Manual Lockdown 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.