Lower

WARNING: Fuel tanks must be vented prior to removal of solenoid valves as described.

CAUTION: Once solenoid valve has been opened by use of override tool, the solenoid valve MUST be replaced.

CAUTION: Use only hand operated tools, NO POWER TOOLS, due to low clearance tolerances on valve threads.


REMOVAL
1. Perform Pre-Service procedures. Service and Repair
2. Vent fuel tanks.
3. Disconnect the fuel lines at the fuel line tube nuts and remove fuel lines.
4. Disconnect the fuel tank solenoid wiring harness from the sensors and solenoids. Remove fuel tank solenoid wiring harness.
5. Remove fittings and sensors from solenoid valve.

NOTE: The fittings for the vent lines are left hand thread.

6. Remove solenoid valve wiring connector.
7. Slowly remove internal fuel tank solenoid valve from tank and allow any residual fuel pressure to vent. Remove fuel tank solenoid valve from tank.

Lower Fuel Solenoid Valves:

INSTALLATION
1. Inspect internal fuel tank solenoid valve and fuel tank threads and clean thoroughly with dry cloth. Lubricate solenoid valve O-ring with clean engine oil and install solenoid valve to tank by hand. If any resistance is felt, remove solenoid valve. Re-inspect and clean threads thoroughly. Tighten solenoid valve to 257-283 Nm (190-208 lb ft).

CAUTION: Replace O-ring seal in the fittings. Lubricate O-ring seals with clean engine oil meeting Ford specification WSS-M2C153-F.

NOTE: Make sure all O-ring sealing surfaces are clean.

NOTE: Natural gas O-rings are identified with a yellow stripe. Do not use unapproved O-rings.

2. Rotate fuel tank(s) in rack as required to align the fuel lines to the fittings. Tighten retainer strap fasteners to 24-29 Nm (18-21 lb ft).

NOTE: Use of a square and flat surface will aid in alignment of solenoid valve fittings to fuel lines.

NOTE: Mark tank to rack location with grease pencil prior to loosening fuel tank straps.

3. Install and align fittings on internal fuel tank solenoid valve parallel to solenoid valve face surface and tighten fittings and positional nuts to 22-28 Nm (34-36 lb ft).
4. Install fuel lines to fuel tank solenoid valves and tighten tube nuts to 34-39 Nm (25-28 lb ft).
5. Install wire harness bracket and fastener to solenoid valve using Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification ESE-M4G204-A2, and tighten fastener to 34-46 Nm (25-33 lb ft). Install fuel tank rack assembly.
6. Refuel tank(s) as necessary.
7. Perform Post-Service procedures. Service and Repair
8. Inspect all fittings and valves. Leak test the complete system.
9. Reinstall stone/heat shield.