Free89W350

Well if you are going to do the upgrade of your fuel lines to a bigger size you should start here https://www.dieseltruckresource.com/...d.php?t=151190. This is a excellent write up but if your like me and have a non innercooled truck your sending unit assembly is different. I ordered the GDP 7/16" Flexible Pick-up Tube Assy and I was trying to figure out how to install this and have a screen on it plus I liked the way that BC847 kept it in the sending unit assembly. So here goes this is what I did.

I am going to skip the removal part which is described in the above mentioned thread. Once I got the sending assembly out I disassembled it and started the thought process. I took the outer plastic off of the unit and laid it out so I could get a length measurement of the factory pick up tube. That way I know where I need to be in the end.



When removing be sure that you keep the factory hose in one piece, you will need it for placement of the black clip that holds the hose in place.



Take notice to the clean section you can see that it has a round mold mark this is where I decided that I was going to install the pick up tube assembly.



I started by drilling a hole with a step drill that went up to 7/8" and then finished the hole with a 1" drill bit. It is just large enough for the bung to slide in snugly which I believe will help it seal better.



I then installed the bung in the top section and tightened it up. On the in tank side of the bung I installed a 3/8" npt x 3/8" hose barb used to tie the next couple of steps together. The next step was to figure out how to incorporate the existing screen (sock) assembly to the 3/8" rubber fuel hose (same thing that BC used).

This is the original set up



I first removed the screen carefully as not to ruin it then I removed the tube (knock it out from the screen side with a punch). I then had this.



If you look at the aluminum piece in the center the hole that the tube came out of is very close to a 1/8" npt tappable hole. I then tapped it out and installed a 1/8" ntp x 3/8" hose barb and put the "sock" back on.



Now at this point you are ready to get your fuel hose cut to length and put it in place. Here is where you will need the original hose so that you can place the plastic holder, which keeps the pick up from moving around. I used two hose clamps above and below the holder to keep it in place. Then I finished the assembly of the whole unit.

Here is how it looks with the new "bigger" line.



For the top fitting (hose to lift pump) I had to make my own because I couldn't find what I wanted at work. I took a 1/2" npt to a compression 90* cut off the compression part and drilled and tapped to accept a 1/8" npt x 3/8" hose barb fitting and installed that. I use 3/8" fuel line from the tank to the pump instead of the "socketless" hose because I had some, that is why I used a hose barb instead of the AN fittings in BC's write up.

I hope that this will help the people with the early 1st Gens that want to do the "Bigger Supply Line" upgrade.

Ryan

G1625S

Really nice work, Ryan

BC847

That's right sporty Ryan. Good write-up too (Sticky Material).

wannadiesel

I kinda figured that's what the pics were for when I approved them. Nice work.

Free89W350

Thanks guys . I hope that this will help fellow Non Intercooled owners.

BC thanks for a great write up, you truly have a nack for excellent teaching.

WOW it made it into the "Sticky" I feel like a kid after on Xmas morning walking out and see a new bike at the tree . Thanks Dave

wannadiesel

No, thank YOU for posting a good writeup.

Bruce M

What is the thing just above the strainer?
Is it a bypass if the strainer gets plugged up?

rbrettctd

Thanks Ryan. I just ordered a BD lift pump kit on Tuesday so this will be highly helpful.

Free89W350

Bruce I am not sure what the technical term is for it but when I tapped it out for the hose barb you could look strait through to the other side. I don't think that it's a bypass but like I said I'm unsure exactly what it is.

Ryan

Free89W350

Randy I hope it helps. If you have any qustions that I aren't answered in the write up please feel free to ask.

Ryan

Bruce M

Ryan,
If you can see through it, could the round part on the side be some kind of
check valve to allow fuel in if the suction strainer gets plugged causing a high vacuum to open it?
I have never heard of a plugged strainer stopping the flow of fuel.
Also you need the fuel to lube the VE Injection Pump.

Free89W350

Yes that is very possible it is kind of a diaphram type mechinism

BearKiller

My 1991 NON-I/C truck has the sending unit exactly like the one in BC847s write-up.

Not sure what the 1990 and the I/C 1991.5 look like.