Ford F150 Pickup. Manual — part 1268

Fig. 23: Identifying Fuel Pump Relay Harness Connector Terminals
Courtesy of FORD MOTOR CO.

Solenoid Stuck Open

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 .

NOTE:

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

2003 Ford Pickup F150

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

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

vented.

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

the fuel tank pressure if the fuel tank solenoid valve was identified as stuck open.

12. Slowly open 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 1 hour.

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

near 0 psi (0 kPa).

14. Remove the fuel tank solenoid manual lockdown valve. See Fig. 15 .

15. Install the Manual Override Tool (134-00050) into the fuel tank solenoid of the tank to be vented.

16. Turn in the override tool jackscrew until fuel flows.

17. Vent the fuel tank until the fuel flow stops.

18. Remove the override tool from the fuel tank solenoid valve.

19. Install the fuel tank solenoid manual lockdown valve.

20. Turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve.

21. Repeat the procedure until all affected tanks are vented.

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

Solenoid Stuck Closed Or Does Not Operate

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 .

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.

WARNING:

Make sure 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.

NOTE:

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

2003 Ford Pickup F150

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

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

Fig. 15 .

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

12. Slowly turn in the 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 venting kit and allow the contents of the fuel tank to vent to the

atmosphere. Venting can take in excess of one hour.

14. Vent the fuel tank until the fuel flow stops.

15. Remove the 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.

FUEL LINE FITTINGS

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.

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

override tool, a new fuel tank solenoid valve must be installed.

WARNING:

DO NOT reuse copper washers in low pressure fittings, always use NEW
copper washers.

2003 Ford Pickup F150

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

Disconnecting (Gyrolok-Type) Fittings

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove the tube nut and slide
nut along fuel line away from fitting. Disconnect fitting. See Fig. 24 .

Swagging (Gyrolok-Type) Fittings

Secure NEW fitting in vice. Position NEW fitting nut, rear ferrule and front ferrule onto NEW line. See Fig.
24 . Install line fully into NEW fitting. Remove Gyrolok fitting nut, ensuring that Gyrolok components are
aligned. Reinstall line and tighten NEW fitting in 2 stages:

z

Stage 1

Tighten tube nut until snug.

z

Stage 2

Tighten an additional 1/2 turn.

Pressurize fuel system and inspect fittings for leaks. See LEAK TEST - ALL BI-FUEL VEHICLES under
FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - BI-FUEL - GASOLINE/CNG article.

NOTE:

When tightening fitting nut, fitting and hose may turn clockwise. Position hose
and fitting a few degrees counterclockwise from desired position. When vehicle
battery is disconnected and reconnected, some abnormal drive symptoms may
occur until vehicle relearns adaptive strategy.

NOTE:

Swagging is required only on new fittings.

2003 Ford Pickup F150

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