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The Dieselfication of Coach 1046
Author: BigRabbitMan (Show all albums)

This album is dedicated to following the process of Coach #1046 being converted from a 1976 Chrysler 440-I with a 4spd Allison AT540 transmission to a 2006 GMC Duramax LBZ turbo diesel with a 6spd Allison 1000 double overdrive transmission. There is a companion discussion thread in the Mechanic's Corner section of the Forum area of this site.
Show Newest Photos First | Show Oldest Photos First379 Photos - Page : [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30] [31] [32]


I used a jig saw to trim the rough cut fuel system adaptor. It is on the left. On the right is the ring that locks the fuel pickup assembly to the adaptor on the left. The edges of the adaptor will be smoothed on a sanding disc later.

On the left is the fuel pickup and guage sending unit. It will slip down into the piece from the top of the old donor tank and then be locked into place by the retaining ring.

Top view of the fuel pickup/return/sending unit.

Here is the side view. The bottom portion has springs inside it that press on the bottom of the two aluminum rods that hold the two halves together. This ensures that the fuel pickup portion is always on the bottom of the tank. The donor tank is 14" deep whereas the FMC tank is 24" so the rods, wire and fuel tubes will need to be extended 10". Note that the guage sending unit is attached to the bottom assembly. More on that later.


Another top view, but this time the ring that will hold the fuel assembly has been put on it. There will be a 3/4" wide steel ring that will hold this assembly to the top of the FMC fuel tank.

This will be the position of the fuel assembly when it is ultimately installed in the FMC fuel tank.

Now it was time to extract the fuel tank from the FMC. Here is the cover for the inspection hole to access the fuel sender/pickup assembly. It is located under the driver side bed and was provided by FMC for coaches #700 and up.

With the cover removed, we see the metal cover for the access hole.


Now we can look down and see the fuel sender/pickup assembly. The first step is to remove the electrical line to the gauge sending unit.

Depending on what smog rules were in effect when a given coach was built, it may have the three lines as shown here or, if prior to the need for a vapor recovery system, only two. If two, one is fuel for the engine and one fuel for the generator. If three, the third one is for the vapor recovery system.

The lines on my coach had hardened to the point that we had to slice the hoses lengthwise to get them to release.

The hold down bolts and sender power wire and the ground wire have been removed and Larry Enoksen, coach #968, is carefully removing the fuel pickup assembly. Be careful as the float for the gauge sticks out sideways and must be manuvered through the small hole.
Show Newest Photos First | Show Oldest Photos First379 Photos - Page : [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30] [31] [32]

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