Upper
DISASSEMBLY1. Perform Pre-Service procedures. Service and Repair
2. Remove upper fuel tank rack assembly.
3. Remove vent box.
4. Disconnect internal fuel tank solenoid wire harness as necessary.
5. Remove two bolts retaining fuel tank straps to rack assembly.
NOTE: Mark fuel tank locations with grease pencil prior to removing fuel tank straps.
6. If required, remove fuel tank solenoid valves.
7. Remove fuel tanks as necessary.
ASSEMBLY
1. Inspect fuel tank rack insulators for deterioration or damage and replace as necessary.
2. Place fuel tank(s) in rack assembly.
NOTE: Tanks must be positioned properly in tank straps. Side to side clearance is critical.
3. Place fuel tank retaining straps over tanks and install retaining bolts until snug.
4. If removed, replace fuel tank solenoid valves.
5. Loosen fuel tank rack retaining strap bolts. Using fuel tubes as reference, rotate fuel tanks in the rack assembly until fuel line connectors align squarely to the solenoid valve fittings.
NOTE: Use of square and flat surface will aid in alignment of solenoid valve fittings to fuel lines.
6. Tighten fuel tank rack assembly retaining strap bolts to 24-29 Nm (18-21 lb ft).
7. Connect internal fuel tank solenoid valve and main fuel shut-off solenoid valve wire harness as necessary.
8. Install pressure and temperature sensors. Tighten pressure sensor to 47-63 Nm (35-46 lb ft). Tighten temperature sensor to 35-45 Nm (26-33 lb ft).
9. Install vent box.
10. Install fuel lines as necessary and tighten O-ring seal fittings to 34-39 Nm (25-28 lb ft).
CAUTION: Replace O-ring seal in the fittings. Lubricate O-ring seals with clean engine oil meeting Ford specification WSS-M2C153-F.
NOTE: Make sure all O-ring sealing surfaces are clean.
NOTE: Natural gas O-rings are identified with a yellow stripe. Do not use unapproved O-rings.
11. Install upper fuel tank rack assembly.
12. Pressurize fuel system as shown in Post-Service procedures. Service and Repair
13. Test for leaks.
14. Install stone/heat shield and luggage compartment close out trim as necessary.