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

Replacing a fuel pump in an RV can be a challenging task, and it's important to know the basics about vehicles to do it yourself. The first step is to identify the location of the fuel pump, which is usually in the fuel tank. In some cases, it may be necessary to drop the fuel tank or cut a hole in the floor to access the pump. Before beginning any work, it is crucial to ensure the area is well-ventilated and there are no sources of ignition nearby. The next step is to disconnect the fuel lines and electrical connections to the pump. It is important to note that fuel pump replacement can be dangerous if not done properly, so if you are unsure, it is best to consult a professional.

Removing the fuel tank

Firstly, assess the location of the fuel tank and plan your approach. In some RVs, the fuel tank is located in an easily accessible area, while in others, it may be tucked away in a more confined space. Identify any potential obstacles, such as water tanks or other components, that may need to be removed or adjusted to access the fuel tank.

Next, prepare the RV for the removal process. Lower the fuel level in the tank as much as possible to reduce the weight and make it easier to handle. Additionally, consider using the RV's fuel pump to empty the tank further if needed.

Once you are ready to begin, use a floor jack to raise the rear part of the RV and gain access to the fuel tank. This will provide you with the necessary space to work and slide the tank out. Place safety stands under the axle for added stability.

Locate and remove the straps or bolts securing the fuel tank in place. Typically, there are four large support brackets with straps that go over the top of the tank and bolt to these brackets. Remove the nuts or bolts securing these straps to the brackets.

Disconnect the filler and vent hoses from the tank. These hoses usually pass through an oval-shaped opening in the frame. Use a small socket to loosen the hose clamps in the tight space between the tank and the frame.

Remove any additional connections to the tank, such as the fuel hose from the generator and the tank vent hose from the Evap metal tube.

Use a jack with a large block of wood to support the tank as you remove the support brackets. Start by removing brackets 2, 3, and 4, and then loosen the front bracket (#1) by removing the top bolt and loosening the bottom bolt to allow it to swivel.

Slowly lower the rear of the tank, ensuring that nothing gets caught or snagged. You may need to use a couple of long 2x4s on the ground to help slide the tank out smoothly.

With the tank angled down, reach up and disconnect the fuel lines and electrical connector. You may need a quick-disconnect tool to release the fuel line connector.

At this point, the tank is ready to be lowered to the ground. Move the jack and block to the front of the tank, raise it slightly, and then push the tank towards the rear to clear the support bracket. Lower the tank completely and verify that all connections have been disconnected.

If needed, you can use a couple of long 2x4s as levers to raise the tank slightly when adjusting the jack or sliding it out.

Finally, clean and treat the bolts and nuts that were removed. They may have rust or debris on them, so use a wire brush to clean them, and then apply a penetrating lubricant to help with reassembly.

Disconnecting the fuel lines

Step 1: Accessing the Fuel Pump

Use a floor jack to raise the rear of your RV's fuel tank. This will create enough space to crawl under and access the fuel pump. Ensure you have enough clearance to work comfortably and safely.

Step 2: Removing the Fuel Tank Straps

The fuel tank is secured by straps and support brackets. Start by removing the nuts that secure the straps to the support brackets. Typically, there are four straps and four large support brackets. Removing these will allow you to lower the tank.

Step 3: Detaching the Filler and Vent Hoses

The next step is to remove the filler and vent hoses from the tank. These hoses pass through an oval-shaped opening in the frame. Use a small socket wrench to loosen the hose clamps due to the limited space between the tank and the frame.

Step 4: Lowering the Fuel Tank

Before lowering the fuel tank, ensure you support it with a jack and a large block of wood. This will prevent damage to the tank and provide stability. Now, slowly lower the rear of the tank, verifying that nothing is getting caught or hung up.

Step 5: Disconnecting the Fuel Lines and Electrical Connector

With the tank at an angle, you can reach the fuel line, return line, and electrical connector. Use a quick-disconnect tool to release the fuel line connector. Also, disconnect the electrical connector. At this point, everything should be disconnected, and you can now lower the tank to the ground and slide it out from under the RV.

Safety Precautions:

• Always work in a well-ventilated area when dealing with fuel systems.
• Ensure there are no open flames or sparks nearby.
• Wear safety goggles and gloves to protect your eyes and hands.
• Have a fire extinguisher nearby in case of any accidents.
• Do not smoke while working on the fuel system.
• Absorb any fuel spills with an appropriate absorbent material.

Disconnecting the electrical connector

Before attempting to disconnect the electrical connector, it is important to ensure that you have safely raised and supported the fuel tank. This can be done by using a floor jack to lift the rear of the motorhome fuel tank and placing safety stands under the axle. You will also need to remove the nuts that secure the straps to the support brackets.

Once the fuel tank is securely in place, you can begin the process of disconnecting the electrical connector. First, locate the electrical connector on the fuel pump. It should be attached to the fuel pump with 3-4 wires. Using the appropriate tools, carefully disconnect the wires from the electrical connector. If you have tools for disconnecting an AC, these should be sufficient.

In some cases, you may need to lower or jack up the rear end of the motorhome to access the fuel pump and electrical connector. This will provide you with more space to work and make the process easier.

After you have disconnected the wires, set aside the electrical connector, and focus on removing the fuel pump itself. Remember to take your time and work carefully to avoid any damage to the RV or injury to yourself.

If you are installing a new fuel pump, refer to the manufacturer's instructions for the correct installation procedure. It is important to ensure that all connections are secure before reinstalling the fuel tank and lowering the motorhome back to the ground.

Replacing the fuel pump

Step 1: Assess the Situation

Before beginning any work, it is important to understand the layout of your RV and the location of the fuel pump. In some cases, the fuel pump may be accessed from the top by cutting a hole in the floor, while in others, it may be necessary to drop the fuel tank to access the pump from below. Evaluate your RV's design and decide on the best approach for accessing the fuel pump.

Step 2: Prepare the Work Area

If you plan to cut a hole in the floor:

• Identify the precise location of the fuel pump and any other components, such as water tanks, that may be in the way.
• Carefully measure and mark the cutting area to avoid any accidental damage to surrounding components.

If you plan to drop the fuel tank:

• Ensure you have sufficient space underneath the RV to work comfortably.
• Prepare the necessary tools and safety equipment, including a floor jack, jack stands, wood blocks, and a drip pan to catch any fuel spillage.

Step 3: Access the Fuel Pump

If you are cutting a hole in the floor:

• Using the appropriate tools, carefully cut the hole in the identified location.
• Remove any necessary components, such as water tanks, to access the fuel pump.

If you are dropping the fuel tank:

• Use a floor jack to raise the rear of the motorhome fuel tank.
• Remove the bolts securing the rear and front straps of the tank.
• Disconnect the vent tube and filler tubes by accessing the clamps and using a ratchet to loosen them.
• Lower the rear end of the tank to access the fuel pump.

Step 4: Remove the Old Fuel Pump

• Disconnect the fuel lines and electrical connectors from the old fuel pump.
• Take note of the routing and positioning of the fuel lines and wires to facilitate the installation of the new fuel pump.
• Carefully remove the old fuel pump from the tank.

Step 5: Install the New Fuel Pump

• Clean the area around the fuel pump mounting point and ensure it is free of debris.
• Position the new fuel pump in place, ensuring it is securely attached to the bottom of the tank, either with a spring-loaded mechanism or zip ties.
• Reconnect the fuel lines and electrical connectors to the new fuel pump, following the routing observed earlier.
• If necessary, cut and replace any deteriorated fuel lines or vent hoses.

Step 6: Reassemble and Test

If you cut a hole in the floor:

• Reinstall any components that were removed and secure them in place.
• Repair the hole in the floor by patching it or installing an inspection cover.

If you dropped the fuel tank:

• Raise the rear of the tank and secure it in place using the support brackets and bolts.
• Ensure all hardware is tightened securely.
• Reinstall the fuel tank straps and tighten the bolts.
• Test the fuel pump by starting the engine and listening for the pump to run for 2-3 seconds when the key is turned to IGN.

By following these steps, you can successfully replace the fuel pump in your RV, ensuring a well-functioning fuel system and improved engine performance.

Reinstalling the fuel tank

To reinstall the fuel tank, you will need to reverse the steps you took to remove it.

First, ensure that the tank is empty or almost empty. Then, slide the tank back into place under the motorhome. Secure the tank to the brackets using the four straps and bolts. Tighten all the bolts and nuts, ensuring that the tank is securely fastened to the brackets.

Next, reconnect the filler and vent hoses to the tank. These hoses go through an oval-shaped opening in the frame, so you will need to use a small socket to loosen the hose clamps. Reconnect the fuel hose to the generator and the tank vent hose to the Evap metal tube located just forward of the left rear wheel on the inside of the frame rail.

Finally, reconnect the fuel lines and electrical connector to the fuel pump. Make sure that all connections are secure before raising the rear of the tank and reinstalling the support brackets.

Once the tank is securely in place, you can start the engine and check for any leaks or issues. If everything looks good, you can lower the motorhome off the jacks and take it for a test drive to ensure that the fuel pump is functioning properly.

Frequently asked questions