Onan BGM Generator fuel pump replacement

[ehhackney]

I'm posting this in hopes that it might help and encourage someone else with the same project facing them.


It turned out that the problem with my generator was the fuel pump, which I replaced. It cost around $50 at the local Cummins distributor. Unless you are absolutely sure that both fuel lines - the one from the metal tank line to the fuel pump and the one from the fuel pump to the fuel filter on the front - are in good shape, I would advise replacing them.


I'm mechanically inclined, but fumble-fingered and most of my tools are junk. The job would have gone easier with a short ¼-drive extension, but I either lost it or it was incorporated into some long-forgotten Rube Goldberg project.


On this generator, the fuel pump sets low on the inside. You can get to it pretty easily from underneath. Two bolts hold the generator on and the ground wire attaches with a third bolt in the generator frame, which also holds the heavy braid ground to the RV chassis. The 12-volt wire is attached by way of a single blade connector. Getting the bolts off and on is cramped and a little fiddly, but can be done.


I knew I had buggered up the rubber fuel hose from the tank line to the fuel pump getting it off, and replaced it. It turned out I also messed up the hose from the fuel pump to the fuel filter in front, but didn't realize it until I got the generator running and noticed a leak. That meant I had to go back and replace that line, too, which turned out to be easier than I expected. Once it is disconnected on both ends it's not that hard to work it out and fish a new one back in. I could do this with the fuel pump in place. I replaced the spring-style hose clamps with screw ones.


I hope this helps someone.


Best regards,


Hack
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