Bounder Fuel Pump Removal from inside of the motorhome
As always be sure to disconnect the batteries before you try the this procedure.
This section is for the repair and replacement of a bounder fuel pump removal with an 80 gallon tank.
I first located the general location of the fuel pump from underneath the motorhome. This is for the fuel pump removal. There is a sump in the tank that shows the general location. I measured from the back of the motorhome to the sump and transferred those measurements to the inside of the motorhome. This put the pump location just under the bed.
Again this is for the bounder fuel pump removal on a 1994 Bounder 28T motor home on a chevy P30 chassis.
You have to unplug the fuel pump for the bounder fuel pump removal operation from the main wiring harness. This is located under the motorhome on the drivers side about the center of the tank along the frame of the motorhome.
Before any work can be done inside the motor home for the bounder fuel pump removal, the fresh water tank has to be removed. It will slide out the driver side of the motor home. You need to remove the water level sensor wires making a note as to how they were removed. Below the water tank is a 1 inch styrofoam bed. This also has to be removed.
After you have the water tank out you now can work on the inside of the motorhome. The first thing to do is remove the bed footer support. This comes off by removing the corner trims. You should be able to pull up on them without breaking them. after they are removed there are about 9 screws holding the support to the floor (3 screws) and 6 screws holding the footer support to the side supports. Then place the support out of the way. The carpet is stapled to the floor so use a pair of pliers to remove the carpet. The plywood under the carpet is screwed to the center support by 3 screws on each side of the plywood sections. Remove the screws then cut out the plywood on each side of the center support.
Floor cutout under the bed.
Under bed cutout with panels removed. Notice the frame member in the center of the picture. Do not cut this member.Floor cutout
After I made the cutout in the floor, I was able to expose the sub floor that is under the water tank and above the fuel tank. This second floor is made up of linoleum, 1/4″ Luan, styrofoam insulation, and a thin piece of sheet metal. This comes to about 1 inch thick. I used a multi tool to cut thru the linoleum, Luan and styrofoam. I then used a utility knife to cut thru the sheet metal. I cut a small hole and searched for the wires and lines going to the pump. When I found that location, I just cutout enough to work on the pump.
Second cutout under the water tank. Cutout is just big enough to remove the fuel pump assembly.
This is the top of the fuel tank after the second cutout under the water tank.
Now that I can access the fuel pump I now have to remove the pump housing from the tank. First I needed to remove the 3 fuel lines from the pump housing. The lines are the fuel supply, the fuel return line and the generator fuel supply line. I then had to remove the locking ring on the top of the pump housing. The lock ring has to be turned counterclockwise until the ring is unlocked.
A non metal drift should be used to prevent any sparks being made when striking the locking ring.
Once the ring is unlocked, pull the housing out of the tank to access the pump. I then took the pump to my shop and replaced the actual fuel pump. I used a Bosch model 69238 fuel pump which is for a 1994 bounder motorhome 28T with an 80 gallon fuel tank.
On the workbench I needed to bend the bottom of the fuel pump mounting bracket to release the fuel pump. After the new pump is installed the bracket can be bent back into place to hold the new pump.
When closing the floor under the water tank I used a piece of fiberglass board with a foil coating on one side. I used plenum board used for HVAC which can be purchased at Home Depot or Lowes. I trimmed the original styrofoam insulation back and down to the metal backing an inch or two to support the plenum board. On the top side of the plenum board I overcut a piece of luan board from an old door I had and glued it to the plenum board and then glued the luan to the existing sub floor.
Plenum board. This floor is under the water tank.
This is the luan placed over the plenum board and glued to the plenum and the water tank floor.I marked the location of the fuel pump on the luan for future use.