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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]


Here are the two fuel filters with hoses attached.


This is my Onan generator without its cover. Since the gas tank has been converted to being a diesel tank, the Onan has been converted to propane as its fuel. The shiny object is the mixer valve that has replaced the gas carburator. Below the deck, a shut off valve has replaced the fuel pump.


The second filter is installed. The fuel will now go from the lift pump to the OEM filter (white object in upper right) and then to the large 2 micron filter and then to the engine. Maintaining fuel purity is very important with diesel engines. This filter arrangement will help achieve long injector life.


I had a bracket made to hold a second fuel filter. The one that will go here is a 2 micron filter.


In this closeup, you can see two things: first is the "mini" sump that I had built into the tank. It is about 1/4 inch deep and 3 inches in diameter. It will collect any heavy particles or small amounts of water that end up in the tank. In the middle of that I had provisions for a drain plug included. But for the plug I am using a Femco drain plug that allows me to very easily drain a cup or so of fluid at any time. What you are seeing is the dust cover as the actual valve mechanism is inside the tank and very safe from damage from road debris


This is the bottom of the fuel tank. It has a stainless steel angle iron piece running along each end near the bottom. Then four bolts that go through rubber grommets, through the angle iron and up into cage nuts in the subframe hold the tank up. No straps to break! Notice the drain provision at the right rear of the tank.


This is all that you can see of the tank from the outside. But it is there!


Today was fuel tank day! It was time to put the new stainless steel fuel tank (shown in earlier photos) into the coach. It was a very tight fit but with the help of Mark H. and Larry E., a floor jack and much wiggling and jiggling we got the tank lifted up into the very tight compartment. Mark is on the left and Larry on the right.


It was time to drop in the first of two batteries. I needed to have the battery there as I will be designing the brackets that will hold the engine control module (ECM) and transmission comtrol module (TCM) in the area to the right of the battery. Also, a stand will be designed that will support the water-to-air intercooler about 2 ft above the battery. The stand will probably use the battery support frame as its base.


From the lift pump, the fuel will go to the OEM fuel filter assembly which also has a manual priming pump on the top and a water sensor on the bottom. I moved it from the bracket that you see on the right to the firewall. It would not fit in the standard location and it is now more assesable as well. The stock filter is a 10 micron filter. I will be adding a second filter downstream of this one that is a 2 micron filter.


The Duramax does not use a lift pump in its OEM installation. It draws the fuel up with the main high pressure pump. I have added a centrifial lift pump down low on the frame that will generate 4# of pressure. In this position the pump has a flooded intake as it is below the level of the fuel tank.


And the lid is placed on top. It is now ready to receive the fuse board and all its connections while maintaining good accessibility.
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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