Special Tool(s) SPECIAL TOOL(S) WARNING: DO NOT MODIFY THE SYSTEM CONFIGURATION OR COMPONENTS OR REPLACE COMPONENTS WITH COMPONENTS NO SPECIFICALLY DESIGNED FOR USE WITH NATURAL GAS. FORD MOTOR COMPANY HAS SPECIFICALLY DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION FOR THE 5.4L F SERIES BI FUEL VEHICLE, AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS CAN PRODUCE AN UNTESTED CONFIGURATION THAT CAN RESULT IN FIRE OR PERSONAL INJURY OR CAUSE ENGINE DAMAGE. IT IS IMPORTANT THAT YOUR BI FUEL VEHICLE BE CORRECTLY MAINTAINED BY FORD BI FUEL TRAINED PERSONNEL. IF A CONCERN OCCURS, IT IS IMPORTANT THAT CORRECTLY TRAINED PERSONNEL DIAGNOSE THE CAUSE. IF A CONCERN RELATES TO THE FUEL SYSTEM, CORRECT PART REPLACEMENT IS IMPERATIVE TO KEEP YOUR VEHICLE OPERATING AT NORMAL PERFORMANCE. BI FUEL COMPONENTS AND GASOLINE SPECIFIC COMPONENTS ARE NOT INTERCHANGEABLE. IF YOUR VEHICLE IS NOT SERVICED IN ACCORDANCE WITH BI FUEL SERVICE PROCEDURES, DAMAGE CAN OCCUR AND YOUR WARRANTY MAY BE INVALIDATED. FUEL SUPPLY LINES ARE ALWAYS PRESSURIZED. WHEN SERVICING FUEL RELATED COMPONENTS, DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE. FLAMMABLE MIXTURES MAY BE PRESENT AND CAN IGNITE, RESULTING IN PERSONAL INJURY. THE NATURAL GAS FUEL SYSTEM IS ALWAYS PRESSURIZED TO 655 KPA (95 PSI) DOWNSTREAM OF THE FUEL PRESSURE REGULATOR AND UP TO 24821 KPA (3,600 PSI) UPSTREAM OF THE FUEL PRESSURE REGULATOR. USE CARE WHEN SERVICING
THE FUEL SYSTEM OR PERSONAL INJURY CAN OCCUR. EYE AND EAR PROTECTION ARE REQUIRED TO BE WORN DURING EVACUATING OR REMOVAL AND INSTALLATION OF FUEL SYSTEM COMPONENTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. DO NOT EVACUATE ANY FUEL TANK UNLESS THE FUEL TANK OR FUEL TANK SOLENOID VALVE IS DAMAGED OR INOPERATIVE AND A NEW FUEL TANK SOLENOID VALVE OR FUEL TANK MUST BE INSTALLED. UNNECESSARY EVACUATING OF GOOD TANKS CAN CAUSE DAMAGE TO THE FUEL TANK SOLENOID VALVE. THE NATURAL GAS FUEL SUPPLY MANIFOLD IS PRESSURIZED TO 655 KPA (95 PSI). FUEL PRESSURE MUST BE RELIEVED PRIOR TO ANY FUEL SYSTEM SERVICE. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED BEFORE ANY COMPONENT CAN BE REMOVED. THE FUEL TANKS MUST BE EVACUATED PRIOR TO TANK REMOVAL. REMOVAL OF COMPONENTS WITHOUT PRESSURE RELIEF OR TANK EVACUATION CAN CAUSE NATURAL GAS TO ESCAPE INTO THE AIR AND CAUSE INJURY OR DEATH. NOTE: The following procedure must be used when removal of the fuel tanks or a fuel tank solenoid valve is required for the replacement of a fuel tank or fuel tank solenoid valve. It is recommended that evacuating be performed with a vent stack. A typical vent stack installation is shown in the Description and Operation portion, this is a typical installation only. Any vent stack must be approved by local authorities. The fuel tank evacuation procedure is accomplished at the fuel fill valve and should only be performed when a damaged, expired, or inoperative fuel tank or fuel tank solenoid valve is detected. The fuel tank venting must be confirmed with the use of the Rotunda Manual Override Tool 134 00050. Once the override tool has been used, a new fuel tank solenoid valve must be installed, as the use of the override tool will destroy the valve. This procedure must be performed to vent any fuel tank with a stuck open or stuck closed solenoid valve or to vent any fuel tank for any reason. 1. Relieve the natural gas fuel pressure.
2. Close and tighten the manual lock downs on all tank(s). 3. Connect the grounding cable. 4. Connect the special tool to the vent stack.
5. Connect the special tool to the fill valve. NOTE: Make sure that the bleed valve on the special tool is closed. 6. Connect the special tool to the special tool.
7. Slowly open the manual backflow valve with a 3/16" alien wrench. 8. Slowly open the jack screw on the manual lock down. The gage on the Fuel Filler Neck Venting Kit should be reading 0 kpa (0 psi). WARNING: IF THE GAGE ON THE FUEL FILLER NECK VENTING KIT IS READING TANK PRESSURE THE SOLENOID IS STUCK OPEN AND THE FUEL TANK MUST BE EVACUATED AND THE SOLENOID REPLACED. DO NOT REMOVE ANY COMPONENT UNTIL THE TANK IS EVACUATED OR PERSONAL INJURY MAY OCCUR. 9. Apply 12 volts directly to the solenoid valve. NOTE: If the gage on the Fuel Filler Neck Venting Tool does not read tank pressure the solenoid may be stuck closed and will have to be evacuated with the manual override tool and the solenoid valve replaced. 10. Slowly open the bleed valve on the Fuel Filler Neck Venting Tool and evacuate the tank until the pressure gage reads 0 kpa (0 psi). NOTE: Evacuation of fuel tank(s) may take in excess of 1 hour per tank.
11. Remove the manual lock down and install the manual override tool in the tank being evacuated then force open the solenoid with the jack screw. CAUTION: Make sure that the forcing rod on the manual override tool is retracted or an uncontrolled release of natural gas may occur. 12. Confirm that the fuel pressure is 0 kpa (0 psi).