Rajan Wilcox
Fuel tank swaps are a common procedure for car enthusiasts and mechanics alike. Whether it's for a Chevy Tri-Five, a GMT400 truck, or a classic Impala, swapping fuel tanks can be done for various reasons, such as extending driving range, adding fuel injection technology, or simply replacing an old or faulty tank. When performing a fuel tank swap, it is important to consider the compatibility of the new tank with the vehicle, ensuring that it fits properly and that the fuel type is suitable. In some cases, modifications may be necessary, such as changing the filler neck or adding coupler fittings for fuel lines. Additionally, it is crucial to take safety precautions, such as avoiding sharp objects that could puncture the tank and ensuring the tank is empty and free of debris before connecting the fuel lines.
Characteristics and Values of Fuel Tank Swaps
| Characteristics | Values |
|---|---|
| Fuel Tank Capacity | 25-gallon, 34-gallon, 100-litre |
| Vehicle Type | Cars, Trucks, SUVs, Motorcycles |
| Process | Disconnect fuel lines, remove old tank, install new tank, connect fuel lines |
| Tools/Equipment | Socket and ratchet, coupler #6AN fittings, siphon hose, floor jack |
| Benefits | Increased fuel capacity, modern sending unit, improved accuracy, baffles to reduce fuel roll |
| Considerations | Tank shape and size compatibility, rust and rot in fuel lines, fuel type compatibility |
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What You'll Learn
A larger fuel tank may not fit in the desired space
When considering a fuel tank swap, it is important to note that simply increasing the size of your fuel tank may not be as straightforward as it seems. While a larger fuel tank can provide increased fuel capacity, it may introduce a host of challenges related to fitment and installation.
One of the primary challenges is ensuring that the larger fuel tank physically fits in the allocated space. In some cases, the larger fuel tank may be longer or have a different shape than the original tank, requiring careful measurement and comparison to determine compatibility. This was the case for a user on an online forum who noted a difference in the shape of a 25-gallon and a 34-gallon fuel tank, requiring creative solutions for a successful swap.
Additionally, the fuel tank's surrounding components and accessories can pose challenges. For example, the fuel pump, which plays a crucial role in delivering fuel from the tank to the engine, may not fit through the opening of the new, larger tank. This issue has been encountered by several individuals, requiring creative solutions such as angling the pump or removing obstructions like plastic tabs. Ensuring a proper seal and addressing any debris or residue in the tank are also important considerations when installing a new fuel pump.
Furthermore, the placement of the fuel filler neck and the front tank strap must be carefully considered. In some cases, a larger fuel tank may require modifications to the mounting location or the use of rear-mounted tanks, as seen in some SUVs and trucks. These modifications can introduce additional costs and complexity to the installation process.
Lastly, it is important to consider the impact of a larger fuel tank on the overall weight and balance of the vehicle. A heavier fuel tank, especially when full, can affect the handling and performance of the vehicle. Therefore, it is crucial to assess whether the desired space can accommodate the larger tank without compromising the structural integrity and safety of the vehicle.
In conclusion, while a larger fuel tank may seem like a straightforward upgrade, it is important to carefully consider the available space and the potential challenges associated with fitment, installation, and vehicle performance. Consulting with a reputable mechanic or seeking advice from online communities with experience in similar fuel tank swaps can help identify potential issues and ensure a successful upgrade.
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Emptying a fuel tank can be done by tilting a car or using a siphon hose
Emptying a fuel tank can be done in several ways, including tilting a car or using a siphon hose.
Tilting a car to empty its fuel tank is not a recommended method, as it can damage the vehicle. However, some people have observed that parking spots that are tilted down away from the pump allow for more fuel to be added to the tank. This is because the air or fume bubble trapped in the tank on a level parking spot can escape through the fill pipe when tilted, making room for more fuel. Overfilling a tank can damage the vapor sorption canister, so it is important to be cautious when attempting to tilt a car for the purpose of emptying the fuel tank.
Using a siphon hose is a more common and effective method to empty a fuel tank. This process involves accessing the top of the tank, typically by removing the back seat and unscrewing the access cap to reach the in-tank fuel pump. One end of the siphon hose is then placed into the tank until it reaches the fuel level, while the other end is put into a gas can. A second hose is inserted into the filler tube, and by blowing into it, the tank is pressurized, initiating the siphon action. Once the fuel starts flowing, the second hose can be removed, and the siphoning process will continue. This method allows for the removal of fuel without the need to mouth siphon, reducing the risk of ingesting gasoline.
Another approach to emptying a fuel tank is to remove the fuel line at the fuel rail and hotwire the fuel pump, or use a scan tool to activate it. However, this method is not recommended as incorrect fuel can damage the pump seals and the filter, and forcing the wrong fuel through the fuel system can cause further issues.
Additionally, some older vehicles may have a drain plug at the bottom of the tank, which can be undone to allow the fuel to flow out. In the absence of a drain plug, creating a hole at the bottom of the tank using a small awl or ice pick can achieve the same result, followed by plugging the hole securely.
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Swapping fuel tanks can improve fuel efficiency
Swapping fuel tanks can potentially improve fuel efficiency, but this depends on several factors, including the vehicle's make and model, the type of fuel, and the specific requirements of the engine.
In some cases, a larger fuel tank may be swapped for a smaller one, which could indirectly improve fuel efficiency by reducing weight and improving mileage. For example, a 25-gallon fuel tank can be swapped for a 34-gallon fuel tank in certain GM trucks, as the larger tank is located in the same place and has a similar shape.
However, it is important to note that simply increasing the fuel tank capacity may not directly translate to better fuel efficiency. The engine's performance and fuel consumption are influenced by various factors, including the quality of fuel, engine design, and driving conditions.
Some products on the market claim to improve fuel efficiency, such as vaporized fuel systems, liquid injection systems, and engine ionizers. Vaporized fuel systems aim to improve combustion by burning the fuel more completely, reducing waste. However, government tests have shown that 99% of the fuel that enters the engine is already burned, making the potential gains from such systems negligible. Liquid injection systems, inspired by WWII fighter planes, inject water or a water-alcohol mixture into the combustion chamber to cool the air, but they may not always deliver significant improvements in fuel economy. Engine ionizers use rubber clips attached to spark plug wires, but they have not been proven to enhance fuel efficiency.
Therefore, while swapping fuel tanks may provide indirect benefits, such as increased fuel capacity or weight reduction, direct improvements in fuel efficiency may be minimal or require additional engine modifications and fuel additives.
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Modern fuel tanks have built-in fuel pumps and sending units
The primary side of the tank, which fills up first, typically contains the pump that provides pressure to the fuel rail. The primary side usually uses a fuel pump module that connects to the vehicle over a serial data bus. The secondary tank contains a transfer pump, also known as a jet pump. Modern saddle-style tanks often use a returnless fuel system that regulates pressure to the fuel rail inside the tank.
Both the primary and secondary wells contain fuel-level sender units, which are critical to the functioning of saddle-style fuel tanks. These sender units determine the fuel level in the tanks for fuel distribution, instrument panel readings, and EVAP testing. The fuel level sent to the driver is based on the two sender inputs. The fuel pump module and the PCM use the senders to determine if the system is operating properly.
In the case of a fault in the secondary side of the tank, the gauge may default to the primary side sending unit reading, resulting in a maximum reading of half-tank. This reading persists until the fuel level on the secondary side is empty, and the fuel on the primary side begins to drop. A fault with the primary-side sender will cause the gauge to read empty.
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A new fuel tank may improve the performance of an older vehicle
While it is unclear whether swapping a fuel tank will improve the performance of an older vehicle, a larger fuel tank will increase the vehicle's fuel capacity, allowing the vehicle to travel further before needing to refuel. However, it is important to note that the feasibility of swapping fuel tanks depends on the specific vehicle and fuel tank in question. For example, when swapping a 25-gallon fuel tank for a 34-gallon fuel tank in a GM truck, some modifications may be necessary due to differences in the shape and size of the tanks.
Additionally, it is worth noting that fuel tank maintenance and cleanliness can impact vehicle performance. A clean fuel tank can improve engine performance and fuel efficiency, as it removes old debris, dirt, and contaminants that have accumulated at the bottom of the tank. This is especially important when installing a new fuel pump, as a dirty fuel tank can damage the new pump.
Furthermore, old gas in the fuel tank can cause issues such as engine knocking, sputtering, and clogged injectors if it is more than a year old. However, gas that is less than two months old will generally not cause any significant performance issues. To address old gas, it can be drained from the tank and replaced with fresh gas, or a fuel stabilizer can be added to slow the breakdown of the gas and improve the quality of the gasoline.
In summary, while a larger fuel tank may not directly improve performance, it can increase the vehicle's range. Maintaining a clean fuel tank and using fresh gas or fuel stabilizers can also help optimize engine performance and fuel efficiency. When considering any modifications or maintenance, it is always recommended to consult a reputable mechanic or refer to manufacturer guidelines for specific vehicles.
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Frequently asked questions
A fuel tank swap involves removing an old fuel tank and replacing it with a new one.
There are several reasons why someone might want to swap their fuel tank. One reason could be to increase fuel capacity. Another reason could be to upgrade to a modern fuel tank with features such as a built-in fuel pump and a sending unit for more accurate fuel readings.
The process involves disconnecting all the fuel lines and removing the old fuel tank. The new fuel tank is then installed, and the fuel lines are reconnected. It is important to ensure that the new tank is compatible with the vehicle and that no sharp objects are used during installation to avoid punctures.
It is important to consider compatibility when swapping fuel tanks. While some vehicles may have interchangeable fuel tanks, others may have unique tank shapes or placements that require specific tanks. It is recommended to consult a mechanic or a vehicle-specific forum for guidance.
Yes, it is crucial to ensure that all other caps for water and oil are closed before beginning the swap. Additionally, it is important to handle the fuel carefully to avoid spills and to dispose of old fuel properly.
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