47–00 Safety Precautions
Safety Precautions in this section apply to all
procedures within this group.
DANGER
When working on the vehicle, shut down the en-
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death.
47–01 Fuel Filter Replacement
Refer to the engine manufacturer’s service manual
for removal and installation procedures.
47–02 Fuel Separator Sight
Bowl Cleaning and
Element Replacement
ConMet Fuel Separator Sight
Bowl Cleaning
The only maintenance necessary on ConMet fuel
separators is to clean the sight bowl, if equipped.
See
Fig. 1.
WARNING
Diesel fuel is flammable and can ignite if exposed
to an open flame, intense heat, or other ignition
source. Do not drain fuel near, or expose fuel
vapor to open flame or intense heat. Exposure to
open flame or intense heat could start a fire, pos-
sibly resulting in personal injury or property dam-
age. When working on a fuel system, have a fire
extinguisher within easy reach.
1. Drain the fuel separator.
2. Unscrew the sight bowl from the fuel separator.
3. Wipe the sight bowl clean using a soft cloth.
4. Lubricate the gasket with a film of oil, and rein-
stall it on the sight bowl. If the gasket appears
dry-rotted or damaged, replace the gasket.
5. Lightly lubricate the threads on the sight bowl
with oil, then thread the sight bowl into the bot-
tom of the fuel separator.
6. Hand-tighten until the gasket is in full contact
with the fuel separator, then tighten an additional
1/4 to 1/3 turn.
7. Check that the drain valve is tightened and
closed.
8. Prime the fuel separator.
8.1 Remove the vacuum breaker fitting and
fill the unit with diesel fuel.
8.2 Replace and close the vacuum breaker
fitting when the unit is full of fuel.
IMPORTANT: The fitting must be air-tight
and the valve closed.
Racor Fuel Separator Element
Replacement
The only service necessary on Racor fuel separators
is to replace the filter element.
Racor 490
WARNING
Diesel fuel is flammable and can ignite if exposed
to an open flame, intense heat, or other ignition
source. Do not drain fuel near, or expose fuel
vapor to open flame or intense heat. Exposure to
open flame or intense heat could start a fire, pos-
sibly resulting in personal injury or property dam-
age. When working on a fuel system, have a fire
extinguisher within easy reach.
1. Drain off some fuel by loosening the vent plug
and opening the drain valve.
2. Disconnect the water sensor and heater connec-
tions, if equipped.
3. Remove the element and bowl, together, by turn-
ing counterclockwise.
4. Remove the bowl from the element, and clean
the O-ring.
5. Apply a coating of clean fuel or motor oil to the
new O-ring and element seal.
Fuel 47
Century Class Trucks Maintenance Manual, January 2016 47/1
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