Solenoid - Stuck Closed Or Does Not Operate

SPECIAL SERVICE TOOL(S)

1. 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.
^ DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS, OR REPLACE 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 ECONOLINE 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.
^ FUEL LINE VENTING IS REQUIRED PRIOR TO FUEL SYSTEM COMPONENT SERVICE.
^ EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING VENTING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS.
^ 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 the Description and Operation portion of this section. This is a typical installation only. Any vent stack installation must be approved by local authorities.
^ Do not vent any fuel tank unless the fuel tank or the fuel tank solenoid valve is being replaced. Unnecessary venting of good tanks can cause damage to the fuel tank solenoid valve.

2. The following procedures are required to be used when venting fuel from the fuel tanks to remove the fuel tanks.







1. Turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve(s).

NOTE: On vehicles equipped with an extended range fuel tank, the jackscrew can be reached through an access hole in the vapor retaining cover.

2. Perform the fuel line venting procedure. Refer to Fuel Tank Venting Pressure Relief. Service and Repair







3. Disconnect the fuel fill line from the fuel fill valve.







4. Connect the fuel filler neck venting hose and adapter to the fuel fill line.







5. Connect the grounding cable to the back side of the fuel fill valve at the fuel line connection.

NOTE:
^ Solenoid diagnostics must be completed on all tank solenoid valves prior to venting.
^ All fuel tank solenoid valves must be in the locked down position.







6. Connect the grounding cable to the ground rod.







7. Connect the fuel filler neck venting kit to the fuel venting hose and adapter.







8. Connect the venting hose assembly to the fuel filler neck venting kit.







9. Connect the venting hose assembly to the vent stack.







10. Remove the manual lockdown valve from the fuel tank solenoid valve of the fuel tank to be vented.







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

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 manual override tool, the fuel tank solenoid valve must be replaced.







12. Slowly turn in the manual 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.
13. Slowly open the bleed valve on the fuel filler neck venting kit and allow the contents of the fuel tank to vent to the atmosphere. Venting may take in excess of 1 hour.
14. Vent the fuel tank until the fuel flow stops.







15. Remove the manual override tool from the fuel tank solenoid valve.







16. Install the fuel tank solenoid manual lockdown valve.







17. Turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve.
18. Repeat the procedure until all affected tanks are vented.







19. Install the fuel fill line onto the fuel fill valve.