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Old 06-22-2021, 08:27 AM   #1
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Onan BMG 5500 fuel pump swap

First post here thank you for having me, I have a 1999 holiday rambler vacationer I picked up from my in-laws for a really good deal. They have had the coach since new and took very good care of it barely used it (35k miles) my father in law regularly had everything serviced and maintained pretty regular.
The generator is the onan BMG 5500 and I’ve determined the fuel pump is done I’ve changed all filters and plugs , pump would run fine when cool when it would get hot it wouldn’t pump at all. I have a nice shiny new one that I plan on installing soon as the rain stops. I located the old one at the worse possible location in the generator cabinet lower right side of the frame mount behind the generator. I crawled underneath and it looks to be in a very tricky spot to get to , I’m not afraid to improvise and I will not hesitate to relocate the new one to a more accessible location and leave the old
One in place and just rerun the fuel lines and wires.
I would prefer not to do this because typically this type of stuff can cause problems later on down the road. I’ve also found the fuel line running from the tank to the pump is very well hidden and I’m not sure how it’s routed thru. If anyone has changed one of these can you please give me some pointers on the best way to access the pump with the least amount of headache? Thanks
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Old 06-23-2021, 06:15 AM   #2
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I tackled the job last night since no one replied maybe this info will help someone else in the future, the pump is mounted in a very difficult spot on this model. The only way to access the pump is over the top of the generator and your doing everything mostly blind you do have to go underneath to remove the lower fuel line to the carb. You will need a 10mm wrench or a 3/8 wrench in my case , looks like someone tried to replace the pump before and rounded all but 1 10mm head off so the 3/8 with some encouragement broke them loose.
The wiring was fairly simple the ground on my replacement was too short I simply spliced the old one in and was able to make it work. I also found that my replacement pump was made upside down to what the original was I didn’t realize this at first until li tried to test the pump after it was installed and it was pumping backwards I removed the hoses and simply flipped it over. I moved it a little higher in the back of the gen tray for easier access just in case I was very tired and frustrated so I ran the generator for a few minutes once changed and has to readjust the altitude mixture on the carb to accommodate the increased fuel from a properly working pump. My hands were wet with sweat and gas so I’m going to wait until this evening to do a proper leak check in the daylight I didn’t see any with the flashlight last night but also at that point I was exhausted and frustrated so a quick 5-10 mins to check this evening won’t hurt anything
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