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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]

With the change from the GM radiator to the Ford radiator, the lower radiator hosing presented a challenge. It was resolved by cutting up the stock GM preformed hose and using two sections of it with a section of preformed hose secured off of the wall at Napa. The right hand section of blue hose has a molded in small hose that will become the return from the coach heater. The middle section has (on the back side) a molded in return line for the water cooled EGR valve from the engine. The black section to the left makes the bends and connection to the radiator outlet.

Another view where you can see the connection to the radiator and the second small line for the return from the EGR valve. The coolant hose turns up and then connects to the mechanically driven water pump that sits low and to the right side of the engine.

This gives a little better view of the line coming back from the EGR cooler. A good flow through this line is important as the sensor for engine temperature is right where the coolant enters this system. Without good flow here, the ECM could receive incorrect temp readings and that would affect engine operation.

Back up topside, the upper radiator hose is now in place. Again, a trimmed off the shelf hose with the right bend was used to connect the radiator to the trimmed stock Duramax hose.

Here is another angle to look at the upper hose. It has been wrapped with belting as a precaution just in case it should contact the radiator housing.

This casting that joins the two hoses has two bungs brazed into it to support other functions. The temperature sensor will be used to control the speed of the engine fan. As you saw earlier, the fan uses a variable speed clutch. This is where the temperature is measured for input to the module that will be controlling fan speed. The small hose pointing down will be the source for coolant for the coach heaters.

Yes!! Coolant has now been installed.

While a lot of time and effort is being expended tracing and connecting wires, it doesn't lend itself to pictures. Here is a bundle of wires that are the extended original wiring harness all neatly labeled as to function. They will be landed in the junction box to numbered connections. From the junction box, the circuits go to the fuses/relays and then on to each function. All of this is also being drawn and labeled on a revised coach electrical schematic drawing. The blue spot behind the fuse panel is the Banks engine tuner. Hidden beside it is the Banks Speedbrake controller that creates/controls the exhaust braking system. The remnants of the original wiring harness that can be seen on the right will disappear.

Here is the radiator for the water-to-air intercooler. It has been plumbed and a small expansion tank (7-Up bottle was just the right size and shape)added. It's electic fan has been added as well.

This is the front bulkhead at the nose of the coach. Two pass-throughs were added so that all of the communication lines and automotive power to and from the dash area can be neatly secured.

These mega fuses will be added up front under the dash to the left of the exising ciruit breaker/relay panel. These fuses will add protection for some major circuits.

Here you see the added fuses to the left of the original relay/circuit breaker panel and to the right you see two added relays. The added relays help divert current away from switches to make things more reliable and safer.
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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