08-22-2024, 03:13 PM
Thanks for the link Richard! . I added it to my saved list.
--Simon
1993 8v92TA #312
96 Newell cranking but not starting
08-22-2024, 06:11 PM
Any recommendations on new flooring on 2004 Newell coach.
08-23-2024, 04:50 AM
Ernie the floor guy
Haskell TX
+1 (817) 475-3991
Haskell TX
+1 (817) 475-3991
Rudy Legett
2003 Foretravel U320 4010
ISM11 450 hp Allison 4000R
Factory Authorized Aqua Hot Repair Center
Southeast Texas Area
09-22-2024, 05:44 PM
Well the saga continued today, went over to the coach to install a new fuel line and check valve. First order of business was to get the coach up in the air so I could get under it to see where the fuel lines run and scope out a path for the new fuel line. Thankfully I was able to get the onboard air compressor going by resetting one of the breakers in the electric panel. I also added my portable air compressor and connected it to the port in the engine compartment. The coach rose up on its bags this time and allowed me to get under to raise it a bit more with my bottle jack.
With the coach up in the air and safely sitting on jackstands I proceeded to roll around under it to figure out the path for the fuel line. So after some contortions under the coach it appeared that the only place to go was where the old fuel line was already located. So we worked on trying to get the old fuel line removed. This was quite the task as if you may remember we left it because it was stuck. There are passages in the frame rail that all the cables and lines run through, they are welded pipe in the bulkhead of the frame, so those are the only way to get through to where the fuel tank resides. I was able to get under and use my pry bar to push on the line and free it up enough that we eventually got it moving. I tied some mule tape on the line and we pulled the old line out, of course the other end took some work to get it through the pipe in the bulkhead as well.
Now the old fuel line was out it was on to getting the new one in. Of course this proved difficult as well, started pulling it from the fuel tank toward the rear of the coach and the end would not go through the bulkhead again. Pulled it back out, after it got stuck, and tried to pull it the other way around. We pulled it from the engine toward the fuel tank, got all the way to the bulkhead again where it stopped and was getting stuck on the edge of pipe again. I pulled it back out and put a screwdriver down in the fuel line to act as a guide to help it find its way through the pipe. This time the screwdriver head went right into the pipe as planned but got stuck, working on it with the prybar again I was able to get it moving slowly a little bit at a time. The area where this is located is just in front of the hydraulic cooler and between the bulkhead wall of the fuel tank bay, the area is maybe 5" or 6" wide so you can only reach up as far as your arm will go which is no where close to where the pipes are, that is why I was having to do all the manipulation with my 3' long pry bar. This all took quite some time, probably the better part of 3 hours or so to accomplish. Thought at this point that we had accomplished the hard part of the job, well maybe not.
I went ahead and assembled the new check valve and a short 12" piece of line connected to the new fuel line to the engine. I started to try to get it on the fitting on the tank, this turned out to be a real issue. The ends of the threads were damaged and the line was not threading on nicely. This took another couple of hours of trying to get the line on the fuel tank fitting. Cleaning up the threads with a file a bit and it eventually was done.
Now I went back to the engine compartment and put the line on the fuel filter, did I mention I put plugs in the fuel line to keep any debris from getting in it, and you guessed it. I forgot to pull the plug out of the line. Luckily after a little bit of trying to prime the system I eventually realized what I had done. My excuse for that was the heat, again another warm day here in Florida and at this point we had been at it for a good 5 or 6 hours. Finally getting fuel to the fuel pump satisfactorily, using my vacuum to pressurize the fuel tank and push fuel to the fuel pump combined with pumping the fuel primer bulb on the fuel filter. We turned it over a couple times but the batteries were not up to the task, we were not getting enough juice and it was turning over too slowly. I then had to turn my truck and trailer around so I could hook up the jumper cables and we turned it over and over again. It took many tries and we could see white smoke emerging from the exhaust for the first time. I knew we were finally getting fuel to the injectors, just not enough for it to fire yet. After some more pumping on the primer bulb and it was starting to gush fuel out at the primer bulb. We knew this was an issue but unfortunately the replacement that came in was not correct and we had to use the old one. Some more cranking and now its turning over good with the jumper cables and its starting to cough and we are getting some black smoke, that's a really good sign. I went up front and gave it part throttle while I was cranking and finally it sprang to life. A bit shakey life but life nonetheless. It was sputtering and running rough and I had to continue pumping on the primer bulb to keep it running. It finally sputtered and shut down again, but we got it to run. We now know it will run once we get a fuel source free of air. We called this a win and decided all that is left to do is get the fuel filter/primer replaced and we think it will be just fine and it will run as it should once its getting fuel without any air.
This was the end of a long hot and hard day but I am very happy to see the engine will run just fine.
The saga will continue when the correct filter housing arrives!
With the coach up in the air and safely sitting on jackstands I proceeded to roll around under it to figure out the path for the fuel line. So after some contortions under the coach it appeared that the only place to go was where the old fuel line was already located. So we worked on trying to get the old fuel line removed. This was quite the task as if you may remember we left it because it was stuck. There are passages in the frame rail that all the cables and lines run through, they are welded pipe in the bulkhead of the frame, so those are the only way to get through to where the fuel tank resides. I was able to get under and use my pry bar to push on the line and free it up enough that we eventually got it moving. I tied some mule tape on the line and we pulled the old line out, of course the other end took some work to get it through the pipe in the bulkhead as well.
Now the old fuel line was out it was on to getting the new one in. Of course this proved difficult as well, started pulling it from the fuel tank toward the rear of the coach and the end would not go through the bulkhead again. Pulled it back out, after it got stuck, and tried to pull it the other way around. We pulled it from the engine toward the fuel tank, got all the way to the bulkhead again where it stopped and was getting stuck on the edge of pipe again. I pulled it back out and put a screwdriver down in the fuel line to act as a guide to help it find its way through the pipe. This time the screwdriver head went right into the pipe as planned but got stuck, working on it with the prybar again I was able to get it moving slowly a little bit at a time. The area where this is located is just in front of the hydraulic cooler and between the bulkhead wall of the fuel tank bay, the area is maybe 5" or 6" wide so you can only reach up as far as your arm will go which is no where close to where the pipes are, that is why I was having to do all the manipulation with my 3' long pry bar. This all took quite some time, probably the better part of 3 hours or so to accomplish. Thought at this point that we had accomplished the hard part of the job, well maybe not.
I went ahead and assembled the new check valve and a short 12" piece of line connected to the new fuel line to the engine. I started to try to get it on the fitting on the tank, this turned out to be a real issue. The ends of the threads were damaged and the line was not threading on nicely. This took another couple of hours of trying to get the line on the fuel tank fitting. Cleaning up the threads with a file a bit and it eventually was done.
Now I went back to the engine compartment and put the line on the fuel filter, did I mention I put plugs in the fuel line to keep any debris from getting in it, and you guessed it. I forgot to pull the plug out of the line. Luckily after a little bit of trying to prime the system I eventually realized what I had done. My excuse for that was the heat, again another warm day here in Florida and at this point we had been at it for a good 5 or 6 hours. Finally getting fuel to the fuel pump satisfactorily, using my vacuum to pressurize the fuel tank and push fuel to the fuel pump combined with pumping the fuel primer bulb on the fuel filter. We turned it over a couple times but the batteries were not up to the task, we were not getting enough juice and it was turning over too slowly. I then had to turn my truck and trailer around so I could hook up the jumper cables and we turned it over and over again. It took many tries and we could see white smoke emerging from the exhaust for the first time. I knew we were finally getting fuel to the injectors, just not enough for it to fire yet. After some more pumping on the primer bulb and it was starting to gush fuel out at the primer bulb. We knew this was an issue but unfortunately the replacement that came in was not correct and we had to use the old one. Some more cranking and now its turning over good with the jumper cables and its starting to cough and we are getting some black smoke, that's a really good sign. I went up front and gave it part throttle while I was cranking and finally it sprang to life. A bit shakey life but life nonetheless. It was sputtering and running rough and I had to continue pumping on the primer bulb to keep it running. It finally sputtered and shut down again, but we got it to run. We now know it will run once we get a fuel source free of air. We called this a win and decided all that is left to do is get the fuel filter/primer replaced and we think it will be just fine and it will run as it should once its getting fuel without any air.
This was the end of a long hot and hard day but I am very happy to see the engine will run just fine.
The saga will continue when the correct filter housing arrives!
Jeff LoGiudice
Temple Terrace, Fl
1984 Bluebird Wanderlodge PT40
1998 Newell 2000 #490
1986 MCI/TMC 102A3 (sold)
09-23-2024, 02:47 AM
On inspection of the old hose and check valve give you any better diagnosis?
1999 45' #504 "Magnolia"
Gravette, Arkansas
1996 40 XL Prevost Marathon
09-23-2024, 04:38 AM
(09-23-2024, 02:47 AM)Jack Houpe Wrote: On inspection of the old hose and check valve give you any better diagnosis?
Unfortunately due to time constraints did not get a chance for an autopsy on those items. I can tell you that the hose was surprisingly stretchy whilst we were pulling it out, surely a signs it was due for replacement. I did want to pull the check valve apart but just ran out of time and energy. When I go back I will try to grab the check valve so I can check it out. I can tell you we were not getting any fuel through the old fuel line/check valve and the new one was supplying fuel just fine.
Jeff LoGiudice
Temple Terrace, Fl
1984 Bluebird Wanderlodge PT40
1998 Newell 2000 #490
1986 MCI/TMC 102A3 (sold)
09-23-2024, 04:53 AM
I'll wait for the next episode. 
1999 45' #504 "Magnolia"
Gravette, Arkansas
1996 40 XL Prevost Marathon
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