Replacing The Fuel Bowl Heater Element: Ap63410 Guide

The Alliant AP63410 Fuel Bowl Heater is a direct-fit replacement designed to prevent fuel gelling in diesel engines during winter. This step-by-step guide will show you how to replace the AP63410 fuel bowl heater element in your vehicle, ensuring optimal performance and reliability.

Drain the fuel bowl and remove the cap and filter

To replace the AP63410 fuel bowl heater element, start by draining the fuel bowl. This can be done by locating the yellow lever or screw at the top or bottom of the fuel bowl and turning it to release the fuel. Place a bucket underneath the engine to catch the fuel, which will come out from a steel tube near the cross member.

It is important to keep the engine off while draining the fuel bowl, as you will hear a gurgling sound coming from the bowl as it empties. Additionally, only drain for a few seconds at a time, as you do not want to drain all the fuel out of the bowl. The water will be at the bottom of the bowl and will drain out first. Repeat the process if there is a lot of water in the bowl.

After draining the fuel bowl, the next step is to remove the cap and filter. This will involve opening the filter lid, which can sometimes create a vacuum and prevent the fuel from draining. Once the lid is open, use a 7/8" crows-foot wrench to remove the black plastic standpipe. It is important to note that the standpipe is left-hand threaded.

With these steps, you will have successfully drained the fuel bowl and removed the cap and filter, ready for the next steps in replacing the AP63410 fuel bowl heater element.

Remove the black plastic standpipe

To remove the black plastic standpipe, you will need a 7/8" crows-foot wrench. The standpipe is left-hand threaded, so rotate it anti-clockwise to loosen. Once it has been broken loose, remove it by hand, being careful not to damage the fuel heater element.

If your standpipe has a 3/4 inch "nut" cast into the bottom, it is the older style. In this case, you will not need to use a wrench, and you will not have the two torx-headed screws that are present in the newer style.

When removing the standpipe, be sure to dip the threads in clean motor oil first.

If you are also replacing the fuel heater element, you will need to remove the wiring harness from the fuel filter assembly. To do this, disconnect the electrical connectors from the fuel filter housing heater and water-in-fuel sensor. Then, remove the wiring harness by maneuvering the connectors one-at-a-time through the opening at the bottom of the housing.

Be careful not to damage the wiring harness, as a replacement can be expensive.

Disconnect the small spade connector

Disconnecting the small spade connector inside the fuel bowl is a delicate task, but with the right tools and technique, it can be done successfully. Here is a detailed, step-by-step guide to help you through the process:

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Before beginning, ensure you have the necessary tools, including a set of slim or needle-nose pliers and a small flat-head screwdriver. These tools will help you carefully pry and disconnect the small spade connector without causing any damage. It is also recommended to wear safety gear, such as gloves and eye protection, to safeguard against any potential hazards.

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Locate the small spade connector inside the fuel bowl on the driver's side. Visually inspect the connector for any signs of corrosion or damage. If corrosion is present, carefully clean the connector before proceeding. This will ensure a better connection and reduce the risk of future issues.

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Using your pliers, gently grip the connector housing, not the wire. Start by wiggling the connector side to side and then carefully prying it open. It's important to never pull on the wire itself, as this can lead to wire damage or detachment. Work slowly and carefully to avoid accidental breakage.

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If the connector is tightly secured, you can use a small flat-head screwdriver for additional leverage. Carefully insert the screwdriver tip into the connector, prying gently from the tip farthest from the wire. This will help create some space between the connector and the wire, making it easier to detach. Always pull away from the flat blade it's connected to, as prying in the wrong direction can cause damage.

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Once you have successfully disconnected the small spade connector, inspect the wire for any signs of damage. Ensure that the wire is intact and securely attached to the connector. If there is any damage to the wire, it may need to be replaced to ensure a reliable connection.

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After inspecting and addressing any issues, you can proceed with the rest of your fuel bowl heater element replacement. Remember to follow the manufacturer's instructions and take your time during the reassembly process.

Replace the heater and ensure the plate doesn't rotate

To replace the heater and ensure the plate doesn't rotate, follow these steps:

Firstly, drain the fuel bowl and remove the cap and filter. Next, remove the black plastic standpipe using a 7/8" crow's foot wrench, noting that the standpipe is left-hand threaded. Disconnect the small spade connector inside the fuel bowl and pull out the heater, being mindful of the plate with the wire attached.

Now, to replace the heater, insert the new heater, ensuring that the little tab on the plate is in the correct position to prevent the plate from rotating when the standpipe is tightened. Secure the spade connector and reinstall the standpipe, filter, and cap.

If you are replacing a heating element in a hot plate, the process is slightly different. First, unplug the hot plate and remove the screws or bolts holding it together. Take off the housing to access the internal components. Use a multimeter to test each electrical component, replacing any faulty parts. When reassembling, ensure the thermal fuse (brown) wires are on the outside, and the heater (white) wires are in the middle.

For a GHD heater plate, the process involves removing the caps covering the hinge pin screws with a screwdriver. Undo the hinge pin, which normally involves a fair amount of force and a cracking sound. Push the hinge pin out, separate the two arms, and remove the cover from the arm by unscrewing. Remove the heater plate sub-assembly and dismantle it by sliding the plastic part off the ceramic plate with caution. Swap the broken parts and reassemble, ensuring the wires are routed correctly.

Reinstall the standpipe, filter and cap

To reinstall the standpipe, filter and cap, screw the standpipe in by hand in a counter-clockwise direction. Ensure that the standpipe is tightened with a 7/8" crows-foot wrench. The standpipe is lefthand threaded, so be sure to tighten it accordingly. Once the standpipe is in place, put the filter and cap back on. Screw the cap on in a clockwise direction, tightening it by hand. Make sure that the cap is on securely before proceeding. Now that the standpipe, filter and cap are reinstalled, your fuel bowl heater element replacement is complete.

Frequently asked questions