Onan
External Fuel Leak
Fuel leak observed around generator, smell of fuel in enclosure
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Cracked or loose fuel hose, Leaking fuel filter seal, Loose injector return line (diesel), Faulty fuel pump or fittings
How to Fix / Troubleshooting
Safety first: Immediately shut down the generator, disable auto-start, and eliminate all ignition sources. Ventilate the area. Fuel leaks are a fire hazard.
- Locate leak source: Visually trace fuel lines from tank connection to engine. Look for wet spots, drips, or stains.
- Tighten fittings: Gently tighten hose clamps and threaded fittings at the fuel filter, pump, and injectors. Do not overtighten plastic fittings.
- Replace hoses: Replace any cracked, swollen, or brittle fuel hoses with fuel-rated hose of the correct size.
- Filter seal: If leak is at the fuel filter, remove and reinstall or replace the filter, ensuring the gasket is properly seated and lubricated.
- Test for leaks: After repairs, pressurize the system (prime or run briefly) and recheck for leaks before returning to service.
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Repair Difficulty
Medium
3/5
Required Part
Fuel Hose Assembly
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