Lower Rack Assembly Tank
SPECIAL TOOL(S)
REMOVAL
WARNING:
^ THE STATUS (STUCK OPEN, NORMAL OPERATION, STUCK CLOSED OR DOES NOT OPERATE) OF EACH FUEL TANK SOLENOID VALVE MUST BE IDENTIFIED PRIOR TO VENTING THE FUEL SYSTEM. REFER TO DIAGNOSIS AND TESTING. VENTING OF THE FUEL SYSTEM WITHOUT IDENTIFYING SOLENOID STATUS COULD RESULT IN AN UNEXPECTED RELEASE OF NATURAL GAS INTO THE ATMOSPHERE, POSSIBLY RESULTING IN INJURY OR PROPERTY DAMAGE.
^ EYE PROTECTION IS REQUIRED WHEN REMOVING OR INSTALLING FUEL SYSTEM COMPONENTS TO AVOID POSSIBLE INJURY.
1. Carry out Pressure Relief-Fuel System.
2. Disconnect the battery ground cable.
3. Raise the vehicle.
4. Tighten the manual lock-down valve jackscrews on the bottom tank assemblies (No.3 and No.4) to 9 Nm (79 Lb/In).
5. Remove the LH rear wheel and tire assembly.
6. Remove the four pin-type retainers and remove the splash flap.
7. Remove the two upper stone shield retaining nuts (LH side shown).
8. Remove the lower stone shield retaining nuts and remove the stone shield.
9. Remove the lower tank rack assembly fuel line connections.
1 Slowly loosen the upper tank rack to lower the tank rack fuel line tube fitting at the top tank of the lower rack (tank No.3) to vent the residual system pressure. Disconnect the fitting once the residual pressure is released.
2 Disconnect the fuel supply line tube nut fitting at the top of the "T" fitting on the top tank of the lower tank rack (tank No.3).
10. Disconnect the upper fuel tank rack assembly wiring harness 8-pin connector and remove the connector from the bracket.
11. Disconnect the lower fuel tank rack assembly wiring harness connector.
12. Remove the exhaust system from the catalytic converter back.
13. Attach the Rotunda Fuel Tank Removal Bracket Set "arms" and secure with the lower retaining pins.
WARNING: THE ROTUNDA FUEL TANK REMOVAL BRACKET SET 303-F010 (014-00470) OR EQUIVALENT MUST BE SECURED TO THE LOWER FUEL RACK ASSEMBLY WITH THE RETAINING PINS OR POSSIBLE DAMAGE TO THE VEHICLE AND POSSIBLE PERSONAL INJURY MAY OCCUR.
14. Line up and install the Powertrain Lift with the Rotunda Fuel Tank Removal Bracket Set or equivalent with the lower tank rack guides. Install the upper retaining pins on the bracket set.
WARNING: THE ROTUNDA FUEL TANK REMOVAL BRACKET SET 303-F010 (014-00470) OR EQUIVALENT MUST BE SECURED TO THE LOWER FUEL RACK ASSEMBLY WITH THE RETAINING PINS OR POSSIBLE DAMAGE TO THE VEHICLE AND POSSIBLE PERSONAL INJURY MAY OCCUR.
15. Remove the four lower fuel tank rack assembly upper bolts (RH side shown).
16. Remove the four lower tank rack assembly lower bolts (RH side shown) and carefully remove the Lower fuel tank rack assembly.
INSTALLATION
1. Raise the vehicle.
WARNING: THE ROTUNDA FUEL TANK REMOVAL BRACKET SET 303-F010 (014-00470) OR EQUIVALENT MUST BE SECURED TO THE LOWER FUEL RACK ASSEMBLY WITH THE RETAINING PINS OR POSSIBLE DAMAGE TO THE VEHICLE AND POSSIBLE PERSONAL INJURY MAY OCCUR.
NOTE:
^ Install new O-ring seals in the fuel line connections. Natural gas approved O-ring seals are identified with a yellow stripe. Do not use unapproved O-ring seals.
^ Lubricate the fuel line O-ring seal with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specification WSS-M2C153-H or equivalent prior to installation to help seal and ease installation.
^ When tightening the fuel line, a torque wrench adaptor must be used with the torque wrench. The use of a torque wrench adaptor will alter the effective torque of the wrench being used. To correct the effective torque, a torque multiplication conversion must be used.
2. Position the lower fuel tank rack assembly to the body. Install the four lower bolts (RH side shown) to the lower rack assembly.
3. Install the four upper bolts (RH side shown) of the lower rack assembly to the body.
4. Disconnect and remove the Rotunda Fuel Tank Removal Bracket Set.
5. Using new O-ring seals, connect the fuel line tube nut fittings. Tighten to the specified torque using a torque wrench adaptor.
6. Reconnect the lower fuel tank rack assembly wiring harness connector.
7. Reconnect the 8-pin upper tank wiring harness connector.
8. Open the manual lock-down jackscrews on fuel tanks No.3 and No.4.
9. Lower the vehicle.
10. Connect the battery ground cable.
11. Pressurize the fuel system. Inspect the fuel system for leaks. Repair any leaks that are found.
12. Raise the vehicle.
13. Install the stone shield and the lower nuts.
14. Install the two stone shield upper nuts (LH side shown).
15. Lower the vehicle.