Replacing Fuel Pump In V10 Rv: Step-By-Step Guide

Changing a fuel pump in an RV can be a challenging task, but with the right tools and knowledge, it is certainly doable. The first step is to drain the fuel tank as much as possible to reduce the weight and make it easier to handle. This can be done by using a siphon or a pump to transfer the fuel to a safe container. Once the tank is drained, the next step is to disconnect the fuel lines, electrical connectors, and EVAP hose from the tank. It is important to have a jack or a support to hold the tank in place while working. With the tank supported, the retaining ring and cover can be removed, providing access to the fuel pump. Taking note of the orientation of the cover and the clips securing the pump, the old pump can be carefully removed, and a new one installed in its place. It is important to clean the sealing surface and install a new gasket before securing the retaining ring and cover. Finally, the fuel lines, EVAP hose, and electrical connector can be reconnected, and the tank can be lifted back into place and secured. It is worth noting that some RVs may have the fuel pump located inside the fuel tank, which can make the process more complicated and may require dropping the tank for access. Overall, changing a fuel pump in an RV requires careful planning, attention to detail, and a good understanding of the fuel system.

Draining the fuel tank

Firstly, use a disconnect tool to remove the line going into the fuel filter. You can then jump the fuel pump relay and pump out the remaining fuel into a gas can. It is important to do this with assistance, as one person can operate the pump while the other holds the gas can. Continue pumping until the flow is reduced to a trickle. This will ensure that only a small amount of fuel remains in the tank, making it lighter and easier to work with.

Next, you will need to position a floor jack under the tank to support it while you remove the bolts. Even if the tank is empty, it is crucial to have a jack under the tank as there are no straps or other fasteners underneath to hold it in place. With the metal skid plate, the entire tank assembly can weigh over 100 lbs, so ensure your jack can support this weight.

Now, you can start to disconnect the fuel lines. To do this, simply insert the disconnect tool into the flared end of the line and push inward, then pull the line straight off. Be careful, as the lines will still contain fuel, and hang them over the frame rail to minimize dripping.

At this point, you can disconnect the electrical connector and the EVAP hose. With all the lines disconnected, you can now slide the tank out from under the RV.

With the tank removed, you can access and replace the fuel pump. This process will be much easier if you have drained the tank beforehand, as a full tank would be extremely heavy and difficult to work with. Remember to take appropriate safety precautions when working with fuel, and always ensure you have assistance when needed.

Removing the fuel lines

To remove the fuel lines, you will need to first relieve the fuel system's pressure. You can do this by removing the gas cap or by pulling the fuel pump fuse. You will also need a fuel line disconnect tool, which is a small, specialised tool for removing the lines from the top of the tank. Most parts stores sell these tools.

Once you have the correct tool, follow these steps:

• Insert the disconnect tool into the flared end of the line.
• Push inward and then pull the line straight off.
• Hang the lines over the frame rail to minimise dripping.

If you have a nearly full tank, you will need to drain the tank first. You can do this by inserting the disconnect tool and pointing the fuel line into a gas can. You can then pump out the fuel.

If you have a nearly empty tank, you can simply use a jack to support the tank while you remove the bolts. There is enough slack in the lines to allow the tank to rest on the ground without tearing anything off.

If you have a partially full tank, you may need to use a jack to raise the suspension as much as possible and then position a floor jack under the tank to support it while you remove the bolts.

Note: Be sure to have a jack under the tank even if it is empty, as there are no straps or other fasteners holding the tank in place besides the four bolts.

Disconnecting the electrical connector

Before beginning, ensure you have the necessary tools, including a fuel line disconnect tool and a floor jack. Start by removing as much fuel from the tank as possible. You can use a fuel line disconnect tool to remove the line going into the fuel filter and direct the fuel into a gas can. Once the tank is nearly empty, position the floor jack under the tank to support it while you remove the bolts.

Next, you will need to disconnect the electrical connector. First, locate the electrical connector by following the fuel lines. It is important to note that there may be limited clearance to access the connector, so you may need to jack up one wheel and come in under the hitch for better access. Once you have located the electrical connector, simply pull it straight off. Be careful not to drop it or damage it, as this could cause electrical issues.

After disconnecting the electrical connector, you will also need to disconnect the EVAP hose. Again, use caution to avoid damaging any components. With these connections disconnected, you can now slide the tank out and begin the process of removing the old fuel pump and installing the new one. Remember to take your time and work carefully to avoid any potential hazards or damage to your RV.

Removing the old pump

To remove the old fuel pump, first drain the fuel tank as much as possible. Disconnect the fuel line from the fuel filter using a disconnect tool. You can then jump the fuel pump relay and pump out the remaining fuel into a gas can.

Next, disconnect the electrical connector and the EVAP hose. You can then slide the tank out. Remove the retaining ring and pull the cover upward, noting the orientation of the cover. The pump assembly is affixed to the bottom of the tank, so you will need to disengage the clips on the side of the pump and pull it out.

Be sure to clean the sealing surface on the tank that the gasket sits on before installing the new pump.

Installing the new pump

Now that you have removed the old pump, it's time to install the new one.

First, take the new pump and put it into the tank, sliding it into place and snapping it in. Next, clean the sealing surface on the tank that the gasket sits on. Then, install the retaining ring.

Now, reconnect the tank by sliding it back under and reconnecting the lines, including the EVAP line. With some required cursing and shouting, position the tank on the jack and lift it into place. Be sure to guide it in between the frame rails. Secure the four bolts, and reconnect the filler lines.

And that's it! You've successfully replaced the fuel pump in your V10 RV.

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