Replacing Uma's Generator Fuel Pump and Filter

Thursday, Aug 14

I fired up the VRRV's onboard 4KW Onan/Cummins generator to fix lunch via the air fryer.

The generator died shortly after I had it running.   Hmmmm.

Did the usual checks, plenty of fuel in the main gas tank, generator air filter was clean.

Much cranking of the generator went nowhere.  I then thought to check for the presence of fuel in the generator's carburetor fuel bowl.  Opening the drain plug screw showed NO fuel.  Dammit.

Unplugging the input gas line from the generator's fuel filter showed NO fuel dribbling out.  Not good.

I traced the whole fuel line all the way back to the fuel tank.  No crimps or bends or crushed portions.

I cranked the fuel pump so much trying to draw fuel from the tank that I think it finally gave up the ghost.  

Belatedly, I thought of a simple test to prove whether the pump worked, it did fine once and then nothing, no sucking.  Dammit.

The fuel filter was looking a bit rusty and old too, so I decided to replace both.

Amazon to the rescue!

The prep work (done on Friday ) to remove the old pump proved the hardest part.  Ended up having to drill out the mounting screw (Torx T27) as I didn't have the right Torx socket bit.

The old fuel filter, a bit rusty looking, but still working.  Probably the original filter as the generator has < 500 hrs on it.  You're supposed to swap it out at that point.

Saturday, August 16

Martha joined me today for a few days of camping and brought the replacement pump and filter with her.

Installation went fine but when I tested for fuel, nothing from the fuel line!

A quick call to RichardM, he suggested blowing some air into the gas line to perhaps unblock it.  

I hooked up the air compressor and since I forgot to uncap the gas tank, managed to introduce enough pressure to force fuel to flow once again out of the input line.  Yay!  

Buttoned everything up, fired up the generator and left it running to start putting away tools.

The generator died within 3 minutes.  Dammit.  Again, out of fuel.

I went to look at it and noticed a small puddle of gas coming from the fuel line about 6 feet or so from the generator!

What I had failed to spot two days ago was a tear in the fuel line!  No wonder the line was empty.  Heck I probably broke the old fuel pump while doing prolonged cranking trying to draw fuel!?  Fortunately, not an expensive item.

Anyways, a drive in the CR-V to Woodland Park's AutoZone and I had a fuel line coupler to repair the line.  I cut out the damaged portion and used the coupler to reconnect the cut fuel line.  Easy Peasy.

All done, ran the generator for a good 30 minutes and no leaks!

I'll me monitoring things closer than usual in terms of generator operation but I'm pretty confident the issue is fixed.  Thanks RichardM!

I'll be some zip tie work later to ensure the fuel line is secure. I wonder how the damage happened.  Oh well.