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Onan gen fuel pump

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Joseph

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Onan gen fuel pump
« on: June 03, 2023, 11:19:05 pm »
My fuel pump is on the way out.  Has anyone changed one out and if so did you relocate it to an easier location for future access?  Iím going after market after seeing the reviews on oem werenít much better than aftermarket. 

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CalCruiser

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Re: Onan gen fuel pump
« Reply #1 on: June 04, 2023, 01:25:31 am »
My fuel pump is on the way out.  Has anyone changed one out and if so did you relocate it to an easier location for future access?  Iím going after market after seeing the reviews on oem werenít much better than aftermarket.

IIRC Ron Dittmer started an old thread on this subject and commented that it was a major PITA to replace.
Goin' where the wind goes...

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Joseph

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Re: Onan gen fuel pump
« Reply #2 on: June 04, 2023, 08:52:05 am »
Yup Iím sure itís a pita.   Iím wondering if it might be easier to get at if I lower the generator and lift the cover.  Lowering the Gen isnít all that hard if you use a motorcycle lift.  Thatís how I gained access to change out the starter.   My biggest mind melt is if there is a way to change the location of the pump. It would make it easier for future replacements.  Iíve been reading and it seems the onan 4000 is known for fuel pump failures.  Just trying to head things off at the pass. Itís one thing to do this at home, another on a road trip.

At any rate, I have my treatments starting again Tuesday and parts should be here Thursday so Iím planning, Good Lord willing, to attempt this next Friday or Saturday.
« Last Edit: June 04, 2023, 10:03:34 am by Joseph »

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Joseph

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Re: Onan gen fuel pump
« Reply #3 on: June 09, 2023, 04:10:52 pm »
Ok so I called a shop to see what they wanted to install a new fuel pump.  2 hours labor= $300. Plus the cost of a pump thru them. (Aftermarket).

After reading Dons endeavor I was determined to relocate the pump and found it a relatively easy project.

It took me 3 hours. This includes relocating the pump to the outside, making a mounting bracket.  Drilling a new hole and remounting the rock guard. ( protecting the pump).
In addition I also installed a heavy toggle switch on the power line to the pump. This allows me the option of running the carb dry for storage. (Still get a few drops drawing the bowl but takes all of a minute)


Costs.  3í of new 1/4Ē fuel line. $8.59.  Fuel pump, I went wild, $32, fuel filter I had on hand and toggle switch $10.43.   Additional wire I had laying around to reach the switch and relocated pump. Same goes for making a mounting bracket; made from metal scraps I had laying around.

Iím not sure on the longevity of these aftermarket pumps but now I can change it with the removal of one bolt (rock guard) and 2 screws.  All in a 15 minute max job that can be done anywhere on the road with a 1/2Ē wrench and a Phillips screw driver.

I purchased a back up just in case.

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KEB

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Re: Onan gen fuel pump
« Reply #4 on: June 10, 2023, 01:36:08 pm »
Sounds like a much needed fix.  Any pictures by chance?

Kevin

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Joseph

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Re: Onan gen fuel pump
« Reply #5 on: June 11, 2023, 11:49:38 am »
No pictures.  All your doing is moving the pump directly outside the cabinet right at the grommet where the fuel filter stick out. So all your doing is installing a longer fuel line, increasing the length of the wiring, drilling a new hole in the rock guard to move it farther out to give room for the pump and in my case adding a toggle switch to cut power to the pump .

First however was figuring out the pump was the issue.   That was confusing at best. Fouled plugs, running for a few hours with surging and smoke, running rich etc..  after changing out the carb and still having the same issue I plug the fuel line and set up a gravity feed.  With the gravity feed it ran perfect.  What happens, and Iíve learned is common on the 4000, is as the pump gets hot it runs sporadically and eventually shuts down as it over heats.  Moving it away from the heat solved this.  I installed a aftermarket clone so time will tell how long it holds up.  I bought an extra and now if it fails itís only a 15-20 job tops to install a replacement

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CalCruiser

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Re: Onan gen fuel pump
« Reply #6 on: June 11, 2023, 05:05:00 pm »
This thread makes me want to change the fuel filter. That looks simple enough, but since itís rated for 500 hrs maybe it belongs on the if itís not broke donít fix it list?
Goin' where the wind goes...

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Joseph

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Re: Onan gen fuel pump
« Reply #7 on: June 12, 2023, 10:24:40 am »
I changed filter  this time only because I had it out. The one I replaced had roughly 100 hours on it. I tried it on the back up pump I bought and it seemed to work perfectly. Iím happy I relocated this pump and filter now.  Doing it on the road would have been a tough option but doable. Having the tools to make a bracket all my drill bits etc isnít something I drag along.

To be honest I think many could do it in 2 hours to my 3. Cancer has slowed me down, not to mention age and then thereís the digging around for a piece of metal to make a plate to mount it on etc.. But now, I could change that pump in 15 minutes easily.

For reference my gen has under 400 hours of use
« Last Edit: June 14, 2023, 03:03:58 pm by Joseph »

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Joseph

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Re: Onan gen fuel pump
« Reply #8 on: June 19, 2023, 05:53:13 pm »
One thing to add if your going to change out or move your fuel pump.  There is NO need to disconnect the circuit board. Take you time and slowly turn the board sideways.  It will come out and out of the way enough to get at the pump.  Itís tight but completely disconnecting and removing the circuit board offers no additional room and alleviates the frustration of trying to disconnect those connections