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Fuel Line Evacuation Using Recovery Equipment > < Fuel System Differential Pressure Check

Transit 2000.5 (01.2000-05.2006)

Fuel System - General Information - Liquified Petroleum Gas (LPG) - Fuel Tank Evacuation Transit 2000.5 (01/2000-05/2006)
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 use of incorrect 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 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 or flames 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 the 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 line.
    For additional information, refer to Fuel Line Evacuation in this section.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Unclip the fuel lines from the chassis.

  1. Unclip the fuel lines from the chassis and slide the heat shield back.

  1. WARNING:
    WARNING:When disconnecting the fuel lines from the fuel tank fuel hoses, thermal protection gloves and eye protection must be worn. Failure to follow these instructions may result in personal injury.
    Disconnect the fuel lines from the fuel tank fuel hoses.
    • Discard the fuel line O-ring seals.

  1. Remove the fuel tank fuel hose locking nuts from the fuel tank fuel hoses and remove from the chassis.
  1. Partially lower the vehicle.
  1. Using a suitable Engine Stand support the fuel tank.

  1. Remove the fuel tank retaining bolts.
  1. NOTE:
    NOTE:Make sure the smaller cylindrical fuel tank stays in contact with the Engine Stand during the raising of the vehicle.
    Partially raise the vehicle until there is a gap of 90mm in height between the larger cylindrical fuel tank and Engine Stand.

  1. NOTE:
    NOTE:In order for the fuel tank to be completely removed from the body, the fuel tank must be removed at an angle.
    Insert a suitable packing material, 90mm in height between the larger cylindrical fuel tank and Engine Stand.
  1. NOTE:
    NOTE:Make sure the fuel tank stays in contact with the Engine Stand during the removal.
    Slowly raise the vehicle until the fuel tank is clear from the vehicle.

  1. Remove the LPG fuel tank PRV protective cover.

  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 LPG fuel tank.

  1. Tighten the PRV adaptor special tool lift nut until LPG gas begins to escape from the fuel tank.
  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 LPG fuel tank.

  1. WARNING:
    WARNING: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.
  1. 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.
    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 from the fuel line connector special tool.

  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. Install the LPG fuel tank PRV protective cover.

Fuel Line Evacuation Using Recovery Equipment > < Fuel System Differential Pressure Check