DAVCO Fuel Pro® 385 and 485

49X mm 47.02.002

    Warning: Fluid circulated through the fuel/water separator may be diesel fuel returned from the engine, or engine coolant. Drain the fuel/water separator only when the engine and fluids have cooled. Draining it when the engine is hot could cause severe personal injury due to scalding.

    If returning fuel is released into the atmosphere, the vapors can ignite in the presence of any ignition source. Do not expose the fuel to, or work with the fuel system near open flame or intense heat. To do so could cause fire, possibly resulting in serious personal injury or property damage.

  1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
  2. Check the fuel level in the fuel filter. Replace the fuel/water separator element only when the filter element is completely covered. If the fuel level has reached the top of the filter element, follow the procedure below to replace the element.
  3. Put a clean receptacle under the fuel/water separator and attach a piece of hose to the drain valve, to direct fuel into the receptacle.The drain valve (Fig., Item 7) has a 3/4-inch (19-mm) slip-on hose connection.

    1. Vent Cap

    2. Clear Cover

    3. Filter Element

    4. Collar

    5. Inlet Port

    6. Outlet Port

    7. Drain Valve

    Fig. 1, DAVCO Fuel Pro 385

  4. Remove the vent cap, shown in Fig., to drain the fuel completely, then close the drain valve.
  5. Using a DAVCO Collar Wrench, shown in Fig., remove the collar and clear cover.

    Fig. 2, DAVCO Collar Wrench

    6. Note: Broken vent cap and collar warranty claims will not be accepted if any tool other than a DAVCO Collar Wrench (part number 482017) is used for removal. During installation, the vent cap is to be hand-tightened only , not tightened with a wrench.

  6. Remove the filter, cover O-ring, and vent cap O-ring. Dispose of them in an environmentally acceptable manner. See Fig..
  7. Clean all threads and sealing surfaces very thoroughly. Even a small amount of dirt will prevent the fuel/water separator from sealing, and an air leak may result.
  8. Install the new filter and grommet assembly and cover O-ring on the housing. Position the filter element so the key is lined up with the keyway on the separator plate of the housing. Use the arrow on the top of the endplate to align the filter. See Fig.. Ensure the filter element is fully seated by firmly pushing on the endplate. The filter should not rotate freely.

    1. Endplate

    2. Arrow

    3. Keyway

    4. Key

    Fig. 3, Positioning the Filter Element

  9. Install the clear cover and the collar. Simultaneously apply downward pressure to the top of the clear cover until it is seated on the body of the lower housing and hand tighten the collar until it no longer spins freely. Using the collar wrench, tighten the cover 18 lbf·ft (24 N·m). This is equivalent to rotating the collar clockwise two or three additional ribs, depending on the specific filter model.
  10. Prime the system
    1. Ensure that the drain valve is closed.
    2. Fill the housing to the top of the filter element with clean diesel fuel.
    3. Install and hand-tighten the vent cap O-ring and vent cap.
    4. Start the engine. When the lubricating oil reaches its normal operating pressure, increase the engine speed to high idle for one to two minutes to purge the air from the system.
    5. While the engine is running, and after the air is purged from the system, loosen the vent cap until the fuel level falls to just above the collar, then hand-tighten the vent cap.
    6. Check for leaks and shut down the engine.
Note:
Parent topic: Fuel/Water Separator Element Checking and Replacement
Document Number: 0000119387
Manual Publication Date: 2024-05-16
Topic Publication Date: 2024-10-31