Removal and Installation
Fuel Tank-Compressed Natural Gas
Warning: Do not modify the system configuration or components, or replace components with parts not specially designed for use with natural gas. Ford Motor Company Ltd... has specially designed the materials, components and system configuration for the 2.0L Contour Compressed Natural Gas vehicles, and each particular system is precisely calibrated for efficient operation. The use of different parts or materials can produe an untested configuration that could result in fire or cause engine damage. Failure to follow these instructions may result in personal injury.
Warning: Fuel supply lines will remain pressurized after 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. Failure to follow this instruction may result in personal injury.
Warning: Fuel system pressure release is required prior to fuel system component service. The fuel tank must be evacuated prior to tank removal. Removal of components without pressure release or tank evacuation can cause natural gas to escape into the air. Failure to follow these instructions may result in personal injury.
Warning: Eye and ear protection are required to be work during venting or removal and installation of fuel system components. Failure to follow these instructions may result in personal injury.
Warning: 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 evacuation of good tanks can cause damage to the fuel tank solenoid valve. Failure to follow these instructions may result in personal injury.
Warning: Always ground the vehicle and natural gas system. High pressure gas escaping can cause static electricity buildup and subsequent sparking. Failure to follow these instructions may result in personal injury.
Warning: Never attempt to tighten or adjust fittings while system is under pressure. Close solenoid valve manual shutoff and release system pressure. Failure to follow these instructions may result in personal injury.
Warning: All compressed natural gas lines must be installed prior to returning the manual shutoff valve to normal operation. Failure to follow this instruction may result in personal injury.
Warning: The fuel system is always pressurized to 689 Kpa (100 psi) from the fuel pressure regulator to the compuvalve and up to 20700 Kpa (3000 psi) upstream of the fuel pressure regulator. Use care when servicing the fuel system. Fuel pressure must be release prior to any fuel system service. Failure to follow these instructions may result in personal injury.
Caution: If the CNG system is being disconnected for an extended length of time, cover all open hose fittings and electrical connections to avoid contamination.
REMOVAL
1. Evacuate the CNG tank.
2. Remove the rear seat base, backrest, and rear seat backing cover.
3. Remove the rear seat supports.
4. Disconnect the electrical connectors J/P120 and J/P340.
5. Disconnect the CNG tank lines.
- Loosen three ribbed hose clamps and slide ribbed hoses back on lines.
- Disconnect the two gyrolok fittings.
- Disconnect vent tube.
6. Remove the tank rear straps and isolators.
7. Remove the tank front straps and isolators.
NOTE: To move the tank requires a minimum of two individuals.
8. Remove the tank.
Installation
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn the strategy.
NOTE: The tank should be located 13 mm (0.5 inch) from the passenger side wall. Position the tank so the valve vent port is perpendicular to the floor.
NOTE: Tighten the gyrolok nut until snug, then tighten an additional 1/2 turn.
1. To install, reverse the removal procedure.
2. Pressurize the CNG system and inspect fittings for leaks.