Engine Controls - Removal & Overhaul & Installation - Cng Ford Econoline I

INTRODUCTION

This article only covers removal, overhaul and installation procedures that are unique to natural gas powered vehicles. Procedures that are the same as gasoline powered models are not included in this article. See appropriate REMOVAL, OVERHAUL & INSTALLATION article. Natural gas powered vehicles utilize special fuel tanks, fuel filler valve, fuel pressure regulator/coalescer filter assembly and fuel lines. (Scheme 24), (Scheme 25) or (Scheme 26).

Scheme 24

Scheme 25

Scheme 26

COMPONENT LOCATIONS

COMPONENT LOCATIONS

FUEL SYSTEM

FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING)

Note. To perform fuel system pressure release, use Fuel Rail Test and Venting Kit (134-00116), Grounding Cable (134-00121) and Venting Hose (134-00118). Manufacturer recommends venting fuel through a vent stack that allows natural gas to be vented outside of repair shop. Vent stack must be approved by local authorities.

Crown Victoria

1. Remove fuel pump relay from power distribution box. Disconnect negative battery cable. Insert grounding spike into earth. Connect grounding cable between grounding spike and fuel injection supply manifold. (Scheme 27)
2. Connect fuel rail test and vent kit hose to Schrader valve on fuel rail. Ensure valve on tester is closed. Connect venting hose to fuel rail test and vent kit manifold.
3. Slowly open bleed valve on fuel pressure test and venting kit manifold and allow fuel to vent to atmosphere for one minute. Close bleed valve. Remove pressure test and venting kit from vehicle. Fuel pressure should be exhausted within one minute. If fuel continues to vent after one minute, fuel shutoff solenoid(s) are stuck open.

Econoline & Pickup

1. Insert grounding spike into earth. Connect grounding cable between grounding spike and fuel injection supply manifold. (Scheme 27)
2. Turn manual lockdown valve jackscrew on each fuel tank solenoid valve. (Scheme 28) Connect fuel rail test and vent kit hose to Schrader valve on fuel rail. Ensure valve on tester is closed. Connect Venting Hose (134-00118) to Fuel Pressure Test And Venting Kit (134-00121) manifold.
3. Remove fuel pump relay from power distribution box. Construct a jumper wire approximately 6" long with spade terminals on each end. Jump fuel pump relay terminals. (Scheme 29)or (Scheme 30).
4. Slowly open bleed valve on fuel pressure vent and test kit manifold and allow fuel to vent to atmosphere for one minute. Close bleed valve and remove pressure test and venting kit from vehicle.

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Disconnecting

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING)»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng__fuel-system-pressure-release-fuel-line). Using Spring Lock Coupling Remover (D87L-9280-B for 1/2" or T83P-19623-C for 5/8"), remove retaining clip from coupling. Place remover over coupling so protrusion is positioned on cage opening side of coupling. (Scheme 31)
2. Close remover over coupling. Push remover into cage opening to release female fitting from garter spring. Separate male and female halves of coupling. Remove tool from disconnected spring lock coupling.

Scheme 31

Connecting

1. Ensure garter spring in cage of male fitting is not damaged. Replace if necessary. Clean all dirt from both pieces of coupling. Check "O" rings for damage. Replace using natural gas approved "O" rings (if necessary).
2. Lubricate "O" rings and inside of female fitting with clean engine oil. Snap fitting together. Install retaining clip onto coupling. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line. (Scheme 27)

Remove air inlet tube(s) as necessary. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING) . Disconnect negative battery cable. Disconnect fuel inlet and return lines. See FUEL LINE CONNECTOR . Disconnect wiring harness connectors from injectors and fuel shutoff solenoid. Remove fuel rail bolts. Remove fuel rails and injectors as an assembly.

Position NEW natural gas approved "O" rings onto fuel injectors. Lightly lubricate "O" rings with clean engine oil. To complete installation, reverse removal procedure. Ensure injectors are properly seated. Tighten fuel rail bolts to specification. See TORQUE SPECIFICATIONS .

Removal & Installation

Note. Fuel pressure regulator and coalescer/fuel filter are removed as an assembly.

1. Relieve fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING)»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng__fuel-system-pressure-release-fuel-line) . Pinch off coolant lines approximately 3" from fuel pressure regulator. Disconnect low pressure fuel line from fuel pressure regulator.
2. Disconnect high pressure fuel line from coalescer/fuel filter. Loosen fitting retaining regulator to coalescer/fuel filter. Remove mounting bracket bolts. Remove regulator assembly. To install, replace natural gas approved "O" rings.

Removal & Installation (Econoline)

Note. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING). If removing fuel tank for replacement of lines or support straps, turn in manual lockdown valve jackscrew on fuel tank solenoid valve. (Scheme 28) Fuel tank assembly may be referred to as midship fuel tank assembly.

1. Disconnect negative battery cable. Raise and support vehicle. Remove stone shield retaining nuts. Remove stone shield. Place matching marks on fuel tank support straps and tank. Disconnect electrical connectors and high-pressure fuel line from fuel tank shutoff solenoid valve. Remove fuel tank shutoff solenoid valve. See «FUEL TANK SHUTOFF SOLENOID»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng) valve.
2. Install Powertrain Lift and Tilting Plate (014-00765) assembly under tank. Secure fuel tank assembly with a plastic tie strap. Remove front fuel tank support strap nut. Remove front fuel tank support strap. Remove rear fuel tank support strap nut. Remove rear fuel tank support strap. Carefully lower fuel tank.
3. To install, reverse removal procedure. Lubricate new "O" ring with 5W-30 engine oil.

Removal & Installation (Pickup)

1. Disconnect negative battery cable. Raise and support vehicle. Remove inboard stone shield retaining nuts. Remove stone shield. Disconnect electrical connectors and high-pressure fuel line from fuel tank shutoff solenoid valve. Remove fuel tank shutoff solenoid valve. Place matching marks on fuel tank support straps and tank. Remove upper stone shield support strap.
2. Install Powertrain Lift and Tilting Plate (014-00765) assembly under tank. Secure fuel tank assembly with a plastic tie strap. Remove rear fuel tank support strap and move aside. Remove front fuel tank support strap retaining bolts. Carefully lower fuel tank.
3. To install, reverse removal procedure. Lubricate new "O" ring with 5W-30 engine oil.

FUEL TANKS (BEHIND AXLE)

Note. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING). If removing fuel tank assembly for replacement of support straps or spacers, turn in manual lockdown valve jackscrews on fuel tank solenoid valves. (Scheme 28) Fuel tank assembly may be referred to as aft-axle fuel tank assembly.

1. Disconnect negative battery cable. Raise and support vehicle. Remove 2 front and 2 rear stone shield retaining bolts. Remove stone shield. Remove 8 fuel tank support strap bolts. Remove fuel tank support strap.
2. Disconnect electrical connectors and high-pressure fuel line from fuel tank shutoff solenoid valve. Remove fuel tank shutoff solenoid valve. See «FUEL TANK SHUTOFF SOLENOID»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng) valve. Install Powertrain Lift and Tilting Plate (014-00765) assembly under tank. Secure fuel tank assembly with a plastic tie strap. Remove front fuel tank assembly retaining nuts. Remove rear fuel tank assembly retaining bolts. Carefully lower fuel tank assembly from vehicle. Remove fuel tanks from fuel tank assembly.
3. To install, reverse removal procedure. Lubricate new "O" ring with 5W-30 engine oil.

FUEL TANK (BED MOUNTED)

Note. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING). Turn in manual lockdown valve jackscrew on fuel tank solenoid valves. (Scheme 28) Fuel tank assembly may be referred to as forward in-bed assembly.

1. Disconnect negative battery cable. Remove in-bed tank assembly cover. Disconnect electrical connector, high-pressure fuel line, and jumper fuel line from bed mounted fuel tank solenoid valve. Place matching marks on upper bed mounted tank straps and tank. Remove upper in-bed fuel tank straps. Position Floor Crane (014-00072), Separator Lift Bar (303-F054), and Lifting Sling (100-D008) over fuel tank. Carefully raise fuel tank assembly from vehicle.
2. To install, reverse removal procedure. Lubricate new "O" ring with 5W-30 engine oil.

FUEL TANKS (LOWER RACK ASSEMBLY)

Note. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING). Disconnect negative battery cable. Raise and support vehicle. Turn in manual lockdown valve jackscrews on bottom tank assemblies. (Scheme 28)

Removal & Installation (Crown Victoria)

1. Remove left rear wheel. Remove 4 splash flap pushpins. Remove 2 upper stone shield retaining nuts. Remove lower stone shield nuts. Remove stone shield. Vent residual system pressure by slowly loosening upper tank rack-to-lower tank rack fuel line tube fitting at top tank of lower rack. Disconnect fitting after residual pressure is released. Disconnect fuel supply line tube nut fitting at top of "T" fitting on top tank of lower tank rack.
2. Disconnect upper fuel rack assembly wiring harness 8-pin connector. Remove connector from bracket. Disconnect lower fuel tank rack assembly wiring harness connector. Remove exhaust system from catalytic converter rearward. Attach Fuel Tank Removal Bracket (303-F010) arms and secure with lower retaining pins. WARNING: Ensure removal bracket set is secured to lower fuel rack assembly with retaining pins or possible vehicle damage or personal injury may occur.
3. Align and install Powertrain Lift and Tilting Plate (014-00765). Install upper retaining pins on bracket arms. Remove 4 lower and 4 upper fuel tank rack assembly bolts. Remove lower fuel tank rack assembly. To install, reverse removal procedure.

Note. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING) . Fuel tank assembly may be referred to as upper rack mounted fuel tank.

1. Disconnect negative battery cable. Remove upper fuel tank rack trunk trim to expose fuel tank rack assembly. Remove trunk rear opening trim plate. Remove nylon nuts. Remove flexible tube shield. Raise and support vehicle. Remove left rear wheel. Remove 4 lower splash flap pushpins. Remove lower splash flap.
2. Tighten manual lock-down valve jackscrews on bottom tank assemblies. Vent system of residual pressure by slowly loosening fuel line tube nut fitting on fuel line to upper tank rack assembly. After system is vented, disconnect fitting. Disconnect upper tank rack assembly wiring harness 8-pin connector. Remove connector from bracket. Remove upper fuel tank rack assembly-to-body bolts above rear axle. Lower vehicle.
3. Remove retaining nuts from flexible tube. Position fuel lines and wiring harness aside in luggage compartment. Remove luggage compartment upper fuel tank rack assembly bolts. Install Fuel Tank Removal Bracket Set (303-F010) into upper fuel tank rack assembly guides. Secure bracket set with retaining pins. WARNING: Ensure removal bracket set is secured to upper fuel rack assembly with retaining pins or possible vehicle damage or personal injury may occur.
4. Using Powertrain Lift (014-00765) and Fuel Tank Removal Bracket Set (303-F010), remove upper fuel tank rack assembly. Adjust bracket as necessary to maintain clearance during removal of upper tank rack. To install, reverse removal procedure.

FUEL TANK VENTING

Solenoids Operable

1. Release fuel pressure from lines. See «FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING)»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng__fuel-system-pressure-release-fuel-line). To vent fuel tank, ensure manual lockdown valve jackscrew on fuel tank is turned in.
2. Connect grounding cable to fuel fill valve. (Scheme 32)or (Scheme 33). Connect fuel filler neck venting kit to fuel filler valve. Connect hose between filler neck venting kit and vent stack that allows natural gas to be vented outside of repair shop. Vent stack must be approved by local authorities.
3. Remove fuel pump relay from power distribution box. Construct a jumper wire approximately 6" long with spade terminals on each end. Connect jumper wire between fuel pump relay terminals. (Scheme 29)or (Scheme 30).
4. Slowly open manual lockdown jackscrew on fuel tank solenoid on tank to be vented. (Scheme 28) Slowly open manual backflow valve on fuel filler valve. Observe gauge pressure on fuel filler neck venting kit. Tank pressure should be indicated.
5. Slowly open bleed valve on fuel filler neck venting kit and allow contents of fuel tank to vent to atmosphere. Venting could take in excess of one hour. When tank is exhausted, close bleed valve on fuel filler neck venting kit. Repeat procedure on all affected tanks.
6. Release any residual pressure from fuel rail. See «FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING)»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng__fuel-system-pressure-release-fuel-line). If fuel tank solenoid does not operate (fuel is not releasing), see «SOLENOIDS INOPERABLE OR STUCK CLOSED»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng__solenoids-inoperable-or-stuck-closed) procedure.

Scheme 32

Scheme 33

Solenoids Stuck Open

1. Release fuel pressure from lines. See «FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING)»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng__fuel-system-pressure-release-fuel-line). To vent fuel tank, turn in manual lockdown valve jackscrew on fuel tank.
2. Connect grounding cable to fuel fill valve. Connect fuel filler neck venting kit to fuel filler valve. Connect hose between filler neck venting kit and vent stack that allows natural gas to be vented outside of repair shop. Vent stack must be approved by local authorities.
3. Slowly open manual lockdown jackscrew on fuel tank solenoid on tank to be vented. (Scheme 28) Slowly open manual backflow valve on fuel filler valve. Observe gauge pressure on fuel filler neck venting kit. Tank pressure should be indicated.
4. Slowly open bleed valve on fuel filler neck venting kit and allow contents of fuel tank to vent to atmosphere. Venting could take in excess of one hour. When tank is exhausted, close bleed valve on fuel filler neck venting kit.
5. Release any residual pressure from fuel rail. See «FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING)»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng__fuel-system-pressure-release-fuel-line). Repeat procedure on all affected tanks.

Solenoids Inoperable Or Stuck Closed

1. Release fuel pressure from lines. See «FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING)»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng__fuel-system-pressure-release-fuel-line). To vent fuel tank, turn in manual lockdown valve jackscrew on fuel tank.
2. Connect grounding cable to fuel fill valve. Connect fuel filler neck venting kit to fuel filler valve. Connect hose between filler neck venting kit and vent stack that allows natural gas to be vented outside of repair shop. Vent stack must be approved by local authorities. WARNING: Once fuel tank solenoid has been opened using manual override tool, fuel tank solenoid must be replaced, as override tool destroys tank solenoid valve.
3. Remove fuel tank solenoid manual lockdown valve and install manual override tool in its place. (Scheme 28) Turn in manual override tool jackscrew. Check pressure gauge on fuel filler neck venting kit. Fuel tank pressure should be indicated. Open bleed valve on fuel filler neck venting kit. Vent fuel tank until fuel flow stops.
4. Release any residual pressure from fuel rail. Refer to «FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING)»(/ford/econoline/i-1985-2013/remont/removal-installation/#engine-controls-removal-overhaul-installation-cng__fuel-system-pressure-release-fuel-line). Remove manual override tool from fuel tank solenoid. Replace fuel tank solenoid valve assembly. Repeat procedure on all affected tanks.

Vent fuel tank pressure. See FUEL TANK VENTING . Ensure fuel tank is completely empty. Gain access to fuel tank solenoid in question. Remove fuel tank if necessary. Disconnect fuel lines as necessary. Disconnect wiring as necessary. Slowly remove fuel tank solenoid and let any residual pressure slowly escape. Remove fuel tank solenoid.

Replace "O" rings. Lubricate "O" rings with clean 5W-30 engine oil. Ensure threads on valve and tank are clean and in good condition. Install components by hand. Inspect threads if resistance is felt during installation. Ensure fuel lines are aligned before tightening. DO NOT cross-thread fittings. Tighten fittings to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Disconnect negative battery cable. Remove upper trunk rack mounted fuel tank. See FUEL TANKS (UPPER TRUNK RACK MOUNTED). Remove 9 vapor vent box bolts. (Scheme 34)

Scheme 34

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• FUEL SYSTEM PRESSURE RELEASE (FUEL LINE VENTING)
• FUEL LINE CONNECTOR
• TORQUE SPECIFICATIONS
• SOLENOIDS INOPERABLE OR STUCK CLOSED
• FUEL TANK VENTING