Replacing Riello Fuel Pumps: A Step-By-Step Guide

Riello fuel pumps are known for their poor vacuum performance on dry starts, so it's important to keep the gear set wet with oil. To replace a Riello fuel pump, you'll need to shut off the fuel tank valve and power to the furnace. Use an Allen wrench to remove the bolts securing the pump to the burner housing. After inspecting the pump coupling, bolt on the new pump and reconnect the lines. If you're converting between a one-pipe and two-pipe system, you'll also need to adjust the return plug and bypass screw.

Shut off the fuel tank valve and power to the furnace

Before you begin to replace a Riello fuel pump, it is important to take the necessary safety precautions. Shutting off the fuel supply and power to the furnace is a crucial first step. This will help prevent any accidental fuel leaks or electrical hazards during the replacement process. Here is a detailed guide on how to do this:

Locate the Fuel Tank Valve: The fuel tank valve is usually located near the oil tank or furnace. It is typically a small handle or knob that controls the flow of fuel from the tank.

Shut Off the Fuel Tank Valve: Turn the valve handle clockwise to the "Off" position. This will cut off the fuel supply to the furnace. Make sure to turn it firmly and securely to ensure a complete shutdown of the fuel flow. Put down cat litter or absorbent material: As you work on the fuel pump, it is likely that some fuel will drip or spill. To avoid a mess and prevent any environmental hazards, it is advisable to put down some cat litter or other absorbent material under the burner. This will help soak up any fuel that may leak or spill during the replacement process.

Locate the Power Source: The power source for the furnace is typically located near the unit or at the main electrical panel. It could be a switch, a breaker, or a fuse, depending on your setup.

Shut Off Power to the Furnace: If your furnace has a dedicated switch, turn it to the "Off" position. If you have a breaker box, flip the corresponding breaker to the "Off" position. Alternatively, if your furnace is connected to a fuse box, remove the fuse. Ensure that whichever method you use, the power supply to the furnace is completely cut off.

Verify Power Disconnection: To ensure safety, it is essential to verify that the power to the furnace is indeed off. You can do this by checking the circuit with a voltage tester or simply trying to turn on the furnace. If the unit does not respond, it means the power has been successfully shut off.

By following these steps, you will have safely shut off the fuel supply and power to your furnace, creating a secure environment for you to begin the replacement of the Riello fuel pump. Remember always to put safety first when working with fuel and electrical systems.

Use cat litter to soak up oil that will drip when you disconnect the fuel line(s)

When replacing a Riello fuel pump, it is important to be prepared for potential oil spills when disconnecting the fuel line(s). To effectively manage this, it is recommended to use cat litter to soak up any dripping oil. Here are some detailed steps and considerations for this process:

First, ensure you have a sufficient amount of cat litter on hand. It is better to have more than you think you need to account for any unexpected spills. Place the cat litter in a shallow tray or container and position it directly underneath the fuel line(s) you will be working on. This will catch any dripping oil and prevent it from spreading. If the fuel line(s) are in a hard-to-reach area, you may need to use a funnel or tube to direct the oil drips into the cat litter.

When disconnecting the fuel line(s), work slowly and carefully to avoid any sudden spills or splashes. As you loosen the connection, allow the oil to drip into the cat litter. Once the line(s) are disconnected, be cautious not to spill any remaining oil in the lines. You can carefully tilt the lines over the cat litter to ensure all oil is absorbed.

Cat litter is an effective absorbent for fresh oil spills. However, it is important to note that it is primarily made of clay and silica. As such, it can become dusty, and the oil-coated litter may need to be handled carefully to avoid spreading oil and dust onto surrounding surfaces. You may want to consider following up with a more comprehensive cleanup using absorbent powders, sawdust, or commercial spill kits for a more thorough remediation.

Additionally, be mindful of your surrounding environment when working with oil. Avoid allowing oil or oil-contaminated litter to come into contact with water sources, as even a small amount of oil can have a significant environmental impact. Always follow local guidelines for the proper disposal of oil-soaked litter and cleaning materials.

By following these steps and staying vigilant, you can effectively use cat litter to soak up oil drips when disconnecting the fuel line(s) during a Riello fuel pump replacement.

Use an Allen wrench to remove bolts securing the pump to the burner housing

To replace a Riello fuel pump, you will need metric Allen wrenches. First, shut off the fuel tank valve and power to the furnace. Put some cat litter under the burner to soak up oil that will drip when you disconnect the fuel line(s).

Now, use an Allen wrench to remove the bolts securing the pump to the burner housing. Once the pump is off, inspect both halves of the pump coupling. If they look okay, you can bolt on the new pump and reconnect the lines.

If you are replacing a Riello F5 burner pump, you will need to bleed the system after replacing the pump. There is an air bleeder fitting on the left side of the burner that looks like a brake bleeder fitting. Crack the fitting a little and you will hear a hiss of air, then restart the burner. When you have a full flow of oil coming out of the bleeder, the burner will also be burning—this is the time to close the bleeder valve (but do not over-tighten it).

Check both halves of the pump coupling

To replace a Riello fuel pump, you'll need to check both halves of the pump coupling. This is an important step to ensure that the pump is functioning correctly and there are no leaks. Here are some detailed instructions to guide you through the process:

First, shut off the fuel supply to the pump by closing the valve on the fuel tank. This will prevent any further fuel leakage during the replacement process. Next, turn off the power to the furnace to ensure safety while working on the fuel pump. Place some cat litter or absorbent material under the burner to catch any fuel that may drip when you disconnect the fuel lines.

Now, use an Allen wrench to remove the bolts securing the pump to the burner housing. Take your time with this step to avoid damaging the bolts or the housing. Once the pump is removed, carefully inspect both halves of the pump coupling. Look for any signs of damage, wear, or leaks. If the coupling appears to be in good condition, you can proceed to the next step.

If the coupling is damaged or worn, you may need to replace it. Consult a professional or refer to the manufacturer's instructions for guidance on replacing the pump coupling. Assuming the coupling is in good condition, you can now install the new fuel pump. Simply bolt on the new pump, ensuring that the coupling is properly aligned and secure.

Finally, reconnect the fuel lines and turn on the fuel supply. Check for any leaks around the pump coupling and ensure that the fuel lines are securely connected. Once you're satisfied that everything is in order, restore power to the furnace and test the burner to ensure it's functioning correctly.

By carefully checking both halves of the pump coupling and following the replacement procedure, you can help ensure the safe and efficient operation of your Riello fuel pump.

Install a two-pipe oil feed system to allow air and oil to return to the oil tank

To install a two-pipe oil feed system, you will need to follow these steps:

Firstly, it is important to understand the current setup of your oil tank. Most heating oil tanks have four openings at the top: the fill pipe, the vent pipe, the float gauge, and an extra opening. The fill pipe is where the driver pumps oil into the tank. The vent pipe allows air to enter and leave the tank during the filling process. Sometimes, this pipe includes a float gauge. The extra opening can be used for additional gauges or equipment, or for connecting a second tank.

If your tank has three openings, you have two options:

• Remove the float gauge: This can be tricky as you need to ensure that the gauge's arm doesn't crash into the interior of the tank. You can find a step-by-step guide on how to do this safely in the provided sources.
• Relocate the feed lines (not recommended for DIY): If your feed lines are on the top of the tank and you want to move them to the bottom, you will need to contact a technician. They will create a vacuum inside the tank to remove the plug without spilling oil and ensure there is no sludge buildup.

Now, to install a two-pipe oil feed system, follow these steps:

• Unscrew the return plug.
• Insert the bypass screw.
• Screw in the return hose.

By installing a two-pipe oil feed system, air and oil will be able to return to the oil tank through the return line. This eliminates the need to manually adjust the pressure adjuster.

Frequently asked questions