LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 94 (Engine Controls - System & Component Tests - EEC-V - NGV) >> Fuel Systems >> Unable To Vent Fuel Tanks Or Fuel Lines >> Testing (Econoline)

Testing (Econoline)

WARNING: This page is about a different car, the 2002 Ford Pickup, 2002 Ford Econoline, 2002 Ford Cutaway, and 2002 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Battery must be fully charged to carry out solenoid diagnostics. Ensure manual lock-down valve jackscrew on midship fuel tank solenoid valve is in open (full counterclockwise) position.

  1. Check Midship Fuel Tank For An Open Solenoid Valve
    Turn ignition off. Connect grounding cable, venting hose assembly and fuel filler neck venting kit to vent stack and fuel fill valve assembly. See Figure and Figure . Vent stack installation must be approved by local authorities. For additional fuel tank venting information, see COMPRESSED NATURAL GAS FUEL TANK EVACUATING under FUEL SYSTEM PRESSURE RELEASE in REMOVAL, OVERHAUL & INSTALLATION - ECONOLINE - NGV article. Close manual lock-down valve jackscrews on forward and rear aft-axle fuel tank solenoid valves and extended range fuel tank solenoid valve, if equipped. See Figure. Tighten jackscrews to 62-79 INCH lbs. (7-9 N.m). Open manual backflow valve on fuel filler valve. Open manual bleed valve on fuel filler neck venting kit for 60 seconds. Close manual bleed valve on fuel filler neck venting kit. Observe and record system pressure on fuel filler neck venting kit gauge. If pressure on gauge is zero psi (zero kPa), go to step  3. If pressure on gauge is more then zero psi (zero kPa), go to next step.

  2. Check Midship Fuel Tank Solenoid Valve Power Circuit For A Short To Voltage

    Ensure ignition is off. Disconnect midship fuel tank solenoid valve connector C3132. Using DVOM, measure voltage between chassis ground and midship fuel tank solenoid valve harness connector C3132 terminal No. 1 (Pink/Black wire). See Figure. Proceed as follows:
    • If voltage is 10 volts or more and vehicle is not equipped with aft-axle fuel tanks, repair short to power Pink/Black wire. See WIRING DIAGRAMS article. Retest system for normal operation.
    • If voltage is 10 volts or more and vehicle is equipped with aft-axle fuel tanks, repair short to power Pink/Black wire and go to step  6. See WIRING DIAGRAMS article.
    • If voltage is less than 10 volts and vehicle is not equipped with aft-axle fuel tanks, replace midship fuel tank solenoid valve and retest system for normal operation.
    • If voltage is less than 10 volts and vehicle is equipped with aft-axle fuel tanks, go to step  6.
    3. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  3. Check Midship Fuel Tank Solenoid Valve Operation
    Ensure ignition is off. Reconnect midship fuel tank solenoid valve harness connector C3132. Connect scan tool to Data Link Connector (DLC). Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe and record system pressure on fuel filler neck venting kit gauge. Press "Stop" button on scan tool. If system pressure reading is zero psi (zero kPa) when "Start" button is pressed, go to next step. If system pressure reading is more than zero psi (zero kPa) when "Start" button is pressed, mark midship fuel tank solenoid valve as "Functions Normally". If vehicle is equipped with aft-axle fuel tanks, go to step  6.
    4. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  4. Check Midship Fuel Tank Solenoid Valve Power Circuit For An Open
    Ensure ignition is off. Disconnect midship fuel tank solenoid valve harness connector C3132. Connect DVOM between chassis ground and midship fuel tank solenoid valve harness connector C3132 terminal No. 1 (Pink/Black wire). See Figure. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe and record voltage reading on DVOM. Press "Stop" button on scan tool. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open in Pink/Black wire and retest system for normal operation. See WIRING DIAGRAMS article. If vehicle is equipped with aft-axle fuel tanks, go to step  6.

  5. Check Midship Fuel Tank Solenoid Valve Ground Circuit For An Open

    Turn ignition off. Using DVOM, measure resistance between chassis ground and midship fuel tank solenoid valve harness connector C3132 terminal No. 2 (Black wire). Proceed as follows:
    • If resistance is 5 ohms or more and vehicle is not equipped with aft-axle fuel tanks, repair open in Black wire. See WIRING DIAGRAMS article. Retest system for normal operation.
    • If resistance is 5 ohms or more and vehicle is equipped with aft-axle fuel tanks, repair open in Black wire and go to next step. See WIRING DIAGRAMS article.
    • If resistance is less than 5 ohms and vehicle is not equipped with aft-axle fuel tanks, replace midship fuel tank solenoid valve and retest system for normal operation.
    • If resistance is less than 5 ohms and vehicle is equipped with aft-axle fuel tanks, go to next step.
    6. NOTE: Ensure manual lock-down valve jackscrew on rear aft-axle fuel tank solenoid valve is in open (full counterclockwise) position.

  6. Check Rear Aft-Axle Fuel Tank For An Open Solenoid Valve
    Reconnect midship fuel tank solenoid valve harness connector C3132. Close manual lock-down valve jackscrew on midship fuel tank solenoid valve. See Figure. Tighten jackscrew to 62-79 INCH lbs. (7-9 N.m). Open manual lock-down valve jackscrew on rear aft-axle fuel tank solenoid valve. Open manual bleed valve on fuel filler neck venting kit for 60 seconds. Close manual bleed valve on fuel filler neck venting kit. Observe system pressure on fuel filler neck venting kit gauge. If pressure reading on gauge is zero psi (zero kPa), go to step  8. If pressure reading on gauge is more than zero psi (zero kPa), go to next step.

  7. Check Rear Aft-Axle Fuel Tank Solenoid Valve Power Circuit For A Short To Voltage

    Ensure ignition is off. Disconnect rear aft-axle fuel tank solenoid valve harness connector C3126. Using DVOM, measure voltage between chassis ground and rear aft-axle fuel tank solenoid valve harness connector C3126 terminal No. 1 (Pink/Black wire). See Figure. If voltage is 10 volts or more, repair short to voltage in Pink/Black wire. See WIRING DIAGRAMS article. Retest system for normal operation and go to step  11. If voltage is less than 10 volts, mark rear aft-axle fuel tank solenoid valve as "Stuck Open". A NEW solenoid valve will be installed after diagnostics have been completed. Go to step  11.
    8. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  8. Check Rear Aft-Axle Fuel Tank Solenoid Valve Operation
    Reconnect rear aft-axle fuel tank solenoid valve harness connector C3126. Connect scan tool to DLC, if not done previously. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe and record system pressure on fuel filler neck venting kit gauge. Press "Stop" button on scan tool. If system pressure reading is zero psi (zero kPa) on gauge when "Start" button is pressed, go to next step. If system pressure reading is more than zero psi (zero kPa) on gauge when "Start" button is pressed, mark rear aft-axle fuel tank solenoid valve as "Functions Normally" and go to step  11.
    9. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  9. Check Rear Aft-Axle Fuel Tank Solenoid Valve Power Circuit For An Open
    Turn ignition off. Disconnect rear aft-axle fuel tank solenoid valve harness connector C3126. Connect DVOM between chassis ground and rear aft-axle fuel tank solenoid valve harness connector C3126 terminal No. 1 (Pink/Black wire). See Figure. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe and record voltage reading on DVOM. Press "Stop" button on scan tool. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open in Pink/Black wire. See WIRING DIAGRAMS article. Retest system for normal operation and go to step  11.

  10. Check Rear Aft-Axle Fuel Tank Solenoid Valve Ground Circuit For An Open

    Turn ignition off. Using DVOM, measure resistance between chassis ground and rear aft-axle fuel tank solenoid valve harness connector C3126 terminal No. 2 (Black wire). See Figure. If resistance is less than 5 ohms, mark rear aft-axle fuel tank solenoid valve as "Stuck Closed". A NEW solenoid valve will be installed after diagnostics are completed. Go to step  11. If resistance is 5 ohms or more, repair open in Black wire. See WIRING DIAGRAMS article. Retest system for normal operation and go to step  11.
    11. NOTE: Ensure manual lock-down valve jackscrew on forward aft-axle fuel tank solenoid valve is in open (full counterclockwise) position.

  11. Check Forward Aft-Axle Fuel Tank For An Open Solenoid Valve
    Reconnect rear aft-axle fuel tank solenoid valve harness connector C3126. Close manual lock-down valve jackscrew on rear aft-axle fuel tank. See Figure. Tighten jackscrew to 62-79 INCH lbs. (7-9 N.m). Open manual lock-down valve jackscrew on forward aft-axle fuel tank solenoid valve. Open manual bleed valve on fuel filler neck venting kit for 60 seconds. Close manual bleed valve on fuel filler neck venting kit. Observe system pressure on fuel filler neck venting kit gauge. If pressure on gauge is zero psi (zero kPa), go to step  13. If pressure on gauge is more than zero psi (zero kPa), go to next step.

  12. Check Forward Aft-Axle Fuel Tank Solenoid Valve Power Circuit For A Short To Voltage

    Ensure ignition is off. Disconnect forward aft-axle fuel tank solenoid valve harness connector C3125. Using DVOM, measure voltage between chassis ground and forward aft-axle fuel tank solenoid valve harness connector C3125 terminal No. 1 (Pink/Black wire). Proceed as follows:
    • If voltage is 10 volts or more and vehicle is not equipped with an extended range fuel tank, repair short to voltage in Pink/Black wire. See WIRING DIAGRAMS article. Replace solenoids marked "Stuck Open" or "Stuck Closed" and retest system for normal operation.
    • If voltage is 10 volts or more and vehicle is equipped with an extended range fuel tank, repair short to voltage in Pink/Black wire and go to step  16. See WIRING DIAGRAMS article.
    • If voltage is less than 10 volts and vehicle is not equipped with an extended range fuel tank, replace forward aft-axle fuel tank solenoid valve and all other solenoids marked "Stuck Open" or "Stuck Closed". Retest system for normal operation.
    • If voltage is less than 10 volts and vehicle is equipped with an extended range fuel tank, mark forward aft-axle fuel tank solenoid valve as "Stuck Open" and go to step  16.
    13. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  13. Check Forward Aft-Axle Fuel Tank Solenoid Valve Operation
    Ensure ignition is off. Reconnect forward aft-axle fuel tank solenoid valve harness connector C3125. Connect scan tool to DLC, if not done previously. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe system pressure on fuel filler neck venting kit gauge. Press "Stop" button on scan tool. If system pressure reading is zero psi (zero kPa) on gauge when "Start" button is pressed, go to next step. If system pressure reading is more then zero psi (zero kPa) on gauge when "Start" button is pressed, mark forward aft-axle fuel tank solenoid valve as "Functions Normally". If vehicle is equipped with an extended range fuel tank, go to step  16. If vehicle is not equipped with an extended range fuel tank, replace solenoids marked "Stuck Open" or "Stuck Closed" and retest system for normal operation.
    14. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  14. Check Forward Aft-Axle Fuel Tank Solenoid Valve Power Circuit For An Open
    Turn ignition off. Disconnect forward aft-axle fuel tank solenoid valve harness connector C3125. Connect DVOM between chassis ground and forward aft-axle fuel tank solenoid valve harness connector C3125 terminal No. 1 (Pink/Black wire). See Figure. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe voltage reading on DVOM. Press "Stop" button on scan tool. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open in Pink/Black wire. See WIRING DIAGRAMS article. If vehicle is equipped with an extended range fuel tank, go to step  16. If vehicle is not equipped with an extended range fuel tank, replace solenoids marked "Stuck Open" or "Stuck Closed" and retest system for normal operation.

  15. Check Forward Aft-Axle Fuel Tank Solenoid Valve Ground Circuit For An Open

    Turn ignition off. Using DVOM, measure resistance between chassis ground and forward aft-axle fuel tank solenoid valve harness connector C3125 terminal No. 2 (Black wire). Proceed as follows:
    • If resistance is 5 ohms or more and vehicle is not equipped with an extended range fuel tank, repair open in Black wire and replace any solenoids marked "Stuck Open" or "Stuck Closed". See WIRING DIAGRAMS article. Retest system for normal operation.
    • If resistance is 5 ohms or more and vehicle is equipped with an extended range fuel tank, repair open in Black wire and go to next step. See WIRING DIAGRAMS article.
    • If resistance is less than 5 ohms and vehicle is not equipped with an extended range fuel tank, replace rear aft-axle fuel tank solenoid valve and any other solenoid marked "Stuck Open" or "Stuck Closed". Retest system for normal operation.
    • If resistance is less than 5 ohms and vehicle is equipped with an extended range fuel tank, mark rear aft-axle fuel tank solenoid valve as "Stuck Closed" and go to next step.
    16. NOTE: Ensure manual lock-down valve jackscrew on extended range fuel tank solenoid valve is in open (full counterclockwise) position.

  16. Check Extended Range Fuel Tank For An Open Solenoid Valve
    Ensure ignition is off. Reconnect forward aft-axle fuel tank solenoid valve harness connector C3125. Close manual lock-down valve jackscrew on forward aft-axle fuel tank. See Figure. Tighten jackscrew to 62-79 INCH lbs. (7-9 N.m). Open manual lock-down valve jackscrew on extended range fuel tank solenoid valve. Open manual bleed valve on fuel filler neck venting kit for 60 seconds. Close manual bleed valve on fuel filler neck venting kit. Observe system pressure on fuel filler neck venting kit gauge. If pressure reading on gauge is zero psi (zero kPa), go to step  18. If pressure reading on gauge is more than zero psi (zero kPa), go to next step.

  17. Check Extended Range Fuel Tank Solenoid Valve Power Circuit For A Short To Voltage

    Ensure ignition is off. Disconnect extended range fuel tank solenoid valve harness connector C3122. Using DVOM, measure voltage between chassis ground and extended range fuel tank solenoid valve harness connector C3122 terminal no. (Pink/Black wire). See Figure. If voltage is 10 volts or more, repair short to voltage in Pink/Black wire, replace any solenoids marked "Stuck Open" or "Stuck Closed". See WIRING DIAGRAMS article. Retest system for normal operation. If voltage is 10 volts or less, replace extended range fuel tank solenoid valve and any other solenoids marked "Stuck Open" or "Stuck Closed" and retest system for normal operation.
    18. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  18. Check Extended Range Fuel Tank Solenoid Valve Operation
    Ensure ignition is off. Reconnect extended range fuel tank solenoid valve harness connector C3122. Connect scan tool to DLC, if not done previously. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe and record system pressure on fuel filler neck venting kit gauge. Press "Stop" button on scan tool. If system pressure reading is zero psi (zero kPa) on gauge when "Start" button is pressed, go to next step. If system pressure reading is more than zero psi (zero kPa) on gauge when "Start" button is pressed, mark extended range fuel tank solenoid valve as "Functions Normally" and replace all other solenoids marked "Stuck Open" or "Stuck Closed". Retest system for normal operation.
    19. NOTE: This procedure will supply power to fuel tank solenoid valve for approximately 30-60 seconds. If time expires, cycle "Start/Stop" button on scan tool to restore power.

  19. Check Extended Range Fuel Tank Solenoid Valve Power Circuit For An Open
    Turn ignition off. Disconnect extended range fuel tank solenoid valve harness connector C3122. Connect DVOM between chassis ground and extended range fuel tank solenoid valve harness connector C3122 terminal No. 1 (Pink/Black wire). See Figure. Turn ignition on. Using scan tool, enter OUTPUT TEST MODE. Press "Start" button on scan tool to command all outputs on. Observe and record voltage reading on DVOM. Press "Stop" button on scan tool. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open in Pink/Black wire and replace any solenoids marked "Stuck Open" or "Stuck Closed". See WIRING DIAGRAMS article. Retest system for normal operation.

  20. Check Extended Range Fuel Tank Solenoid Valve Ground Circuit For An Open

    Turn ignition off. Using DVOM, measure resistance between chassis ground and extended range fuel tank solenoid valve harness connector C3122 terminal No. 2 (Black wire). If resistance is less than 5 ohms, replace extended range fuel tank solenoid valve and any other solenoids marked "Stuck Open" or "Stuck Closed". Retest system for normal operation. If resistance is 5 ohms or more, repair open in Black wire and replace any solenoids marked "Stuck Open" or "Stuck Closed". See WIRING DIAGRAMS article. Retest system for normal operation.
scientia non olet · About LEMON Manuals