Well finally got around to pulling the generator apart to get at that damn fuel pump. I am amazed at how much crap I had to pull out to get at the damn pump. If I meet the Onan Design Engineer in a dark alley it won’t be pretty… lol.
You have to:
1. Disconnect main +12vdc to the starter solenoid (so I’d recommend disconnect battery).
2. Remove starter solenoid.
3. Remove main electronics unit (don’t forget to unplug large connector underneath).
4. Remove fuel line hoses from plastic clips on side of generator so you have slack.
5. Remove fuel pump and thankfully with the slack we just made you can pull the entire unit out of the generator and work on it more easier.
6. Swap pump/filter and re-install
7. Reconnect large connector under electronics unit.
8. Slide electronics unit back into place (that rear foot is a pain to get into the slot…enjoy…I nearly lost it on this one).
9. Once rear foot is properly slot, smash down all the wiring and hoses until you can get those two front screws installed. My god what a horrible design. There is TONS of room, no need to smash all that stuff under there. Good luck, checking for leaks, or any loose connections as you can’t see it afterwards.
10. Reinstall solenoid and power.
11. Drink something very strong and swear like a sailor for an hour or two.
My pump made nice noises but didn’t pump any fuel. Amazon cheap parts to the rescue. I almost felt bad not using original Onan parts until I looked at the “factory” fuel filter… the Onan label is a bloody decal… filter is made in China.
I suspect the fuel pump is as well but Cummins Canada wants like $500 for the pump…Amazon you get an entire service kit for $50 (well that was the price lol). Crazy markup on the factory part.
https://www.amazon.ca/gp/product/B09HHD9WCD
If I get another pump failure I’m relocating it to outside the generator so I can easily access it without taking half the generator apart. Oh what fun lol.
One side note was the ground, you would have to unbolt the main ground to get at the fuel pump ground which is a huge pain in the you know what, so I cut the old ground wire and use a Wago to make exchanging easier in the future.
You have to:
1. Disconnect main +12vdc to the starter solenoid (so I’d recommend disconnect battery).
2. Remove starter solenoid.
3. Remove main electronics unit (don’t forget to unplug large connector underneath).
4. Remove fuel line hoses from plastic clips on side of generator so you have slack.
5. Remove fuel pump and thankfully with the slack we just made you can pull the entire unit out of the generator and work on it more easier.
6. Swap pump/filter and re-install
7. Reconnect large connector under electronics unit.
8. Slide electronics unit back into place (that rear foot is a pain to get into the slot…enjoy…I nearly lost it on this one).
9. Once rear foot is properly slot, smash down all the wiring and hoses until you can get those two front screws installed. My god what a horrible design. There is TONS of room, no need to smash all that stuff under there. Good luck, checking for leaks, or any loose connections as you can’t see it afterwards.
10. Reinstall solenoid and power.
11. Drink something very strong and swear like a sailor for an hour or two.
My pump made nice noises but didn’t pump any fuel. Amazon cheap parts to the rescue. I almost felt bad not using original Onan parts until I looked at the “factory” fuel filter… the Onan label is a bloody decal… filter is made in China.
I suspect the fuel pump is as well but Cummins Canada wants like $500 for the pump…Amazon you get an entire service kit for $50 (well that was the price lol). Crazy markup on the factory part.
https://www.amazon.ca/gp/product/B09HHD9WCD
If I get another pump failure I’m relocating it to outside the generator so I can easily access it without taking half the generator apart. Oh what fun lol.
One side note was the ground, you would have to unbolt the main ground to get at the fuel pump ground which is a huge pain in the you know what, so I cut the old ground wire and use a Wago to make exchanging easier in the future.
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