Ford F150 Pickup. Manual — part 1265

Fig. 12: Removing Fuel Tank Shield
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - F150 Pickup - Bi-Fuel - Gasoline/CNG

Fig. 13: Locating Fuel Tank Valve Connectors
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - F150 Pickup - Bi-Fuel - Gasoline/CNG

Fig. 14: Locating ALT Fuel Switch
Courtesy of FORD MOTOR CO.

Compressed Natural Gas Fuel Tank Evacuating

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. Fuel line venting is
required prior to fuel system component service.

WARNING:

Do not modify the system configuration or components, or install
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 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.

WARNING:

Eye and ear protection are required to be worn during venting, or removal
and installation, of fuel system components.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - F150 Pickup - Bi-Fuel - Gasoline/CNG

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

Solenoid Functions Normally

1. Turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve(s). See Fig. 15 .

2. Release the fuel system pressure. See COMPRESSED NATURAL GAS FUEL LINE VENTING .

3. Disconnect the fuel fill line from the fuel fill valve. See Fig. 16 .

4. Connect the Fuel Venting Kit (164-R0911) and Adapter (134-00255) to the fuel fill line. See Fig. 17 .

5. Connect the Grounding Cable (134-00121) to the fuel fill line connection. See Fig. 18 .

6. Connect the grounding cable to the ground rod.

7. Connect the Fuel Filler Neck Venting Kit (134-00117) to the venting hose assembly and adapter. See Fig.

19 .

8. Connect the fuel venting kit to the fuel filler neck venting kit. See Fig. 20 .

9. Connect the venting hose assembly to the vent stack. See Fig. 21 .

10. Remove the fuel pump relay from the power distribution box.

11. Construct a jumper wire from 6" (152 mm) of 18 gauge wire and two spade terminal ends.

12. Jumper the fuel pump relay circuit between terminals No. 87 and 30. See Fig. 22 and Fig. 23 .

13. Slowly open the manual lockdown valve jackscrew on the fuel tank solenoid valve of the fuel tank to be

vented.

14. Observe the gauge pressure of the fuel filler neck venting kit. The pressure should be at tank pressure if

the fuel tank solenoid valve was identified as, "functions normally".

15. Slowly open the bleed valve on the venting kit and allow the contents of the fuel tank to vent to the

atmosphere. Venting can take in excess of one hour.

16. Close the bleed valve on the venting kit, and observe the gauge pressure. The pressure should be at or

near 0 psi (0 kPa).

WARNING:

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:

Do not vent any fuel tank unless a new fuel tank or a new fuel tank solenoid
valve is installed. Unnecessary venting of good tanks can cause damage to the
fuel tank solenoid valve.

NOTE:

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

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.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - F150 Pickup - Bi-Fuel - Gasoline/CNG