ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Fuel System Leak Test > < Fuel System Service Precautions

Focus 1999 (08.1998-12.2004)

Fuel System - General Information - Liquified Petroleum Gas (LPG) - Fuel Tank Evacuation Focus 1999 (08/1998-12/2004)
General Procedures

Special Tool(s)

Pressure Release Valve (PRV) Adaptor

310-108 (23-068-05)

Connector, fuel line

310-092 (23-065)
General Equipment
LPG recovery and transfer unit
  1. WARNING:
    WARNING:Do not modify the system configuration or components, or install components not specially designed for use with alternative fuels. Ford Motor Company Ltd has specially designed the materials, components and system configuration for alternative fuel vehicles, and each particular system is precisely calibrated for efficient operation. The incorrect use of parts or materials can produce an untested configuration that could result in fire, or cause engine damage. Failure to follow these instructions may result in personal injury.
    WARNING:
    WARNING:The fuel tank and lines must be evacuated before attempting any repairs. Failure to follow this instruction may result in personal injury.
    WARNING:
    WARNING:Never attempt to tighten or adjust fittings while the system is pressurized. Failure to follow this instruction may result in personal injury.
    WARNING:
    WARNING:The LPG fuel tank must not be evacuated to atmosphere. Use recovery equipment at all times. Failure to follow this instruction may result in personal injury.
    WARNING:
    WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
    WARNING:
    WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
    WARNING:
    WARNING:The evacuating area must be clearly identified with signs warning against smoking and the use of naked lights within the vicinity. There must be no drains or pits where LPG or vapor could accumulate. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
    WARNING:
    WARNING:Allow the vehicle to stand for five minutes after the evacuation procedure has been carried out to allow LPG vapor to disperse. Failure to follow this instruction may result in personal injury.
    WARNING:
    WARNING:When evacuating an LPG system thermal protection gloves and eye protection must be worn at all times. Failure to follow these instructions may result in personal injury.
    WARNING:
    WARNING:Always disconnect the vehicle battery ground cable before commencing any service or repair procedure. Failure to follow this instruction may result in personal injury.
    WARNING:
    WARNING:All gas lines must be installed prior to reconnecting the battery. Failure to follow this instruction may result in personal injury.
    CAUTION:
    CAUTION:If the alternative fuel system is being disconnected for an extended length of time, cover all open hose fittings and electrical connections to avoid contamination.
    Evacuate the fuel lines.
    For additional information, refer to Fuel Line Evacuation Using Recovery Equipment - in this section.
  1. Open the tailgate and remove the luggage compartment protective floor covering.

  1. Remove the luggage compartment liners.

  1. Remove the air tight housing cover from the air tight housing.

  1. Disconnect the fuel tank solenoid valve electrical connector.

  1. Remove the fuel tank solenoid valve solenoid.

  1. Install the fuel line connector special tool to the PRV adaptor special tool.

  1. NOTE:
    NOTE:Make sure the PRV adaptor special tool lift nut is positioned next to the PRV adaptor special tool locking nut before installation.
    Install the PRV special tool and tighten the PRV special tool locking nut.
  1. WARNING:
    WARNING:Always connect the LPG recovery and transfer unit ground cable to the vehicle before proceeding to the next step. Failure to follow this instruction may result in personal injury.
    Connect the LPG recovery and transfer unit ground cable and fuel line connector to the LPG fuel tank.

  1. Tighten the PRV adaptor special tool lift nut until LPG gas begins to escape from the fuel tank (LPG recovery and transfer unit fuel line connector shown disconnected for clarity).
  1. WARNING:
    WARNING:Before the LPG fuel tank is evacuated the fuel line connector and PRV special tool must be checked for leaks. Failure to follow this instruction may result in personal injury.
    Check the fuel system for leaks.
    For additional information, refer to Fuel System Leak Test - in this section.
  1. WARNING:
    WARNING:The LPG recovery and transfer unit should not be disconnected from the vehicle during the evacuation procedure. Failure to follow this instruction may result in personal injury.
    WARNING:
    WARNING:The LPG recovery equipment must be operated in accordance with the manufacturer's instructions. Failure to follow this instruction may result in personal injury.
    NOTE:
    NOTE:The time taken to carry out the evacuation of the fuel tank will depend on ambient air temperature.
    Using the LPG recovery and transfer unit evacuate the fuel tank.

  1. NOTE:
    NOTE:Before any work can be carried out on the LPG fuel tank, make sure the pressure gauge on the LPG recovery equipment is at 0 bar. Failure to follow this instruction may result in personal injury.
    Loosen the PRV adaptor special tool lift nut (LPG recovery and transfer unit fuel line connector shown disconnected for clarity).
  1. WARNING:
    WARNING:The LPG recovery equipment must be operated in accordance with the manufacturer's operating instructions. Failure to follow this instruction may result in personal injury.
    Turn off the LPG recovery and transfer unit equipment.
  1. WARNING:
    WARNING:Always disconnect the recovery equipment fuel line from the vehicle before proceeding to the next step. Failure to follow this instruction may result in personal injury.
    Disconnect the LPG recovery and transfer unit from the fuel line connector special tool.
    • Disconnect the LPG recovery and transfer unit ground cable from the vehicle.

  1. NOTE:
    NOTE:Make sure the PRV lift nut is positioned next to the PRV locking nut before removal.
    Loosen the PRV adaptor special tool locking nut and remove the PRV adaptor special tool.

  1. Remove the fuel line connector special tool from the PRV adaptor special tool.
  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

Fuel System Leak Test > < Fuel System Service Precautions