REMOVAL AND INSTALLATION / Procedure revision date: 06/21/1999
Solenoid Valve
Special Tool(s)/ Natural Gas Vehicle (NGV) Pressure Test And Venting Kit.
134-00114 or equivalent.
Removal
WARNING: The fuel system will remain pressurized after engine shutdown. This pressure must be relieved before servicing the fuel system. The fuel tanks must be vented prior to removal of the solenoid valves or possible personal injury or property damage may result.
WARNING: Eye protection is required when removing or installing fuel system components to avoid possible injury.
CAUTION: Once the solenoid valve has been opened by the use of the override tool (Manual Override Tool 134-00050, part of NGV Pressure and Venting Kit 134-00114 or equivalent), a new solenoid valve must be installed as use of the override tool will destroy the solenoid valve.
CAUTION: Use hand tools only when working with the solenoid valves as power tools will destroy the low clearance tolerances on the solenoid valve threads and cause possible fuel leakage.
- Carry out Pressure Relief—Fuel System. For additional information, refer to Section 310-00B .
- Remove the fuel tank rack assembly being serviced. For additional information, refer to Tank — Lower Rack Assembly or Tank — Rear Rack Assembly or Tank — Upper Rack Assembly in this section.
- Disconnect the electrical connections from the fuel tank assemblies (upper tank rack shown).
- Disconnect the fuel temperature sensor electrical connector.
- Disconnect the fuel pressure sensor electrical connector.
- CAUTION: When removing the fuel tank solenoid valve electrical connector, it is possible for the connector pins to disengage from the solenoid valve.
Remove the fuel tank solenoid valve electrical connector.
- Remove the screws.
- Remove the fuel tank solenoid valve electrical connector.
- NOTE: The fuel vent line fittings (upper fuel tank rack assembly only) are left-hand thread.
Remove the fuel line connections (upper fuel tank rack assembly shown).
- Remove the fuel line tube nut fittings.
- Remove the fuel vent line fittings (upper fuel tank rack assembly only).
- NOTE: The fuel tank positional fittings are left-hand thread.
Remove the solenoid sensors and the positional fittings (upper fuel tank rack shown).
- Using a backup wrench, remove the solenoid fuel tank pressure and temperature sensors.
- Remove the positional "elbow" and "T" fittings from the solenoid valve as necessary.
- Slowly remove the fuel tank solenoid valve and allow any residual pressure to vent. Remove the solenoid valve from the tank.
Installation
- NOTE: Install a new fuel tank solenoid O-ring seal.
NOTE: Use only natural gas approved O-ring seals. These O-ring seals are identified with a yellow stripe.
NOTE: Make sure all O-ring sealing surfaces are clean.
NOTE: Thoroughly inspect and clean fuel tank solenoid valve threads. If any resistance is felt when installing the solenoid valve, remove and reinspect and clean the solenoid valve threads.
NOTE: Lubricate the fuel tank solenoid O-ring seal with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help seal and ease the installation.
Install the fuel solenoid valve.
- WARNING: The maximum gap between the solenoid valve and the fuel tank sealing surface must not be exceeded. If the gap is exceeded, fuel leakage may occur resulting in a flammable mixture, which could ignite and cause personal injury.
Check the gap between the solenoid valve and the tank-sealing surface in the center portion of each hexagonal flat with a feeler gauge. The gap must not exceed .05 mm (.002 inch). The feeler gauge must be inserted to a depth of 1.6 to 3.1 mm (.06 to .12 inch) to make sure the measurement is accurate. If the gap exceeds the allowable limit, remove the valve, inspect the sealing surfaces, lubricate and install a new seal and repeat the tightening and inspection procedure.
- NOTE: If necessary, loosen the tank straps to slightly turn the fuel tank(s) to align the fittings with the fuel lines.
Install the fuel solenoid connections (upper fuel tank rack shown).
- Install and align the positional fittings.
- Install the fuel pressure sensor.
- Install the fuel temperature sensor.
- Install the fuel line tube nut fittings. On the upper fuel tank rack only, install the fuel vent line fittings.
- Install the electrical connector.
- Install the electrical connector.
- Install the electrical connector retaining screws.
- Connect the fuel tank temperature and pressure sensor electrical connectors.
- Install the fuel tank(s). For additional information, refer to Tank — Lower Rack Assembly or Tank — Rear Rack Assembly or Tank — Upper Rack Assembly in this section.
- Carry out the Fuel System Leak Test procedure. For additional information, refer to Section 310-00B .