Katerina Swanson
Connecting a second diesel fuel tank is a complex process that requires careful planning and execution. It involves making connections between the two tanks to ensure a smooth flow of fuel and prevent leaks. One common method is to use a Y connector or a T connection to join the supply lines, return lines, and vent lines of both tanks, allowing for equilibrium in fuel levels. Some people opt for a gravity feed system, connecting the tanks with hoses at the top and bottom, while others prefer using fuel selector valves, transfer pumps, and toggle switches to manage fuel transfer. Legal considerations and safety precautions, such as preventing fuel leaks and ensuring proper ventilation, are also crucial aspects to address when connecting a second diesel fuel tank.
Characteristics and Values Table for Connecting a Second Diesel Fuel Tank
| Characteristics | Values |
|---|---|
| Filler pipe | Cut the pipe and add a "tee" to connect to the auxiliary tank |
| Fuel transfer | Use a fuel pump to transfer fuel from the auxiliary tank to the main tank when it gets low |
| Vent line | Pump fuel into the main tank's vent line via another tee |
| Fuel gauge | The truck's fuel gauge may not read accurately when transferring fuel while driving |
| Pump and valve | Consider replacing the pump and valve to prevent potential rust issues |
| Leak prevention | Use a hose at the bottom for fuel flow and a hose at the top for air movement; ensure legal compliance |
| Plumbing design | Join supply, return, and vent lines with Y or T connectors to maintain equilibrium and fuel level balance |
| Fuel selector valve | Use a toggle switch to change between tanks; the second tank can read off the in-dash gauge |
| Fuel tank options | Consider the size, placement, and type (stock or aftermarket) of the second tank |
| Legal considerations | Research the legalities of dual fuel tank setups, including fire hazards and rollover valves |
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What You'll Learn
Filling up two tanks
Another option is to connect the two tanks with a hose at the bottom for the fuel to flow in and out, and a hose at the top for air movement. This setup creates a gravity feed system, allowing fuel to be drawn from either tank without the need for an additional pump. However, it is important to consider the legalities of such an arrangement due to the potential fire hazard from leaks.
A third option is to plumb the tanks together, creating a single large fuel supply. This can be achieved by joining the supply lines with a Y-connector, along with the return and vent lines. This setup ensures equilibrium between the tanks, maintaining the same fuel level in both.
Some vehicles with dual tanks have a primary tank that should be filled first. However, in some cases, it may be necessary to fill up one tank, turn the vehicle around, and then fill the other tank, which can be inconvenient and time-consuming.
It is worth noting that some forum users have suggested using a dual-circuit ball valve or a manual dual-port valve to switch between the two tanks, while others recommend using a fuel selector valve, a connector harness, and a toggle switch to alternate between the tanks.
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Using a transfer pump
The process begins by mounting the second tank in a suitable location, such as under the spare tire area or at the rear of the vehicle. The tanks are then connected using hoses or pipes. One hose is placed at the bottom of the tanks to allow fuel to flow in and out, while another hose at the top enables air movement.
A transfer pump is installed to facilitate the movement of fuel between the tanks. This pump can be electric or manually operated, depending on the specific setup and preferences. The pump is usually connected to a switch or momentary switch, allowing the user to control when fuel is transferred from one tank to another.
It is important to consider the placement of the transfer pump and ensure it is accessible for maintenance or replacement. Additionally, some vehicles may require the installation of a second fuel gauge to monitor the fuel level in the auxiliary tank.
When using a transfer pump, it is crucial to take precautions to prevent leaks and ensure the safety of the system. This may include the use of appropriate valves, filters, and other components to maintain the integrity of the fuel transfer system. Regular maintenance and monitoring of the system are also recommended to identify any potential issues promptly.
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Avoiding leaks
Connecting a second diesel fuel tank is a complex process that requires careful consideration to avoid leaks. Here are some detailed instructions and tips to help prevent leaks when connecting a second diesel fuel tank:
Firstly, it is important to understand the potential risks associated with leaks. Diesel fuel leaks can cause significant damage and be very expensive to repair if not caught quickly. Even a small pinhole leak can lead to major issues, so it is crucial to take the necessary precautions during the installation process.
One way to avoid leaks is to keep the plumbing and switching system simple. A complex setup with multiple connections increases the chances of leaks. Consider using a dual-circuit ball valve that switches both the supply and return lines simultaneously. This simplifies the process and reduces potential leak points.
When connecting the two tanks, ensure that the fuel lines are securely attached and free from damage. Use high-quality fuel hoses with chafe guards to protect against abrasion and potential cuts, which could lead to leaks. Additionally, consider installing a filter/water separator in the common supply line to prevent tank crud from building up and causing blockages or leaks.
It is also important to regularly rotate the use of the tanks. This helps prevent the fuel from becoming stale and allows you to identify any fuel hose problems early on. By actively using both tanks, you can catch potential leaks before they become more serious.
Finally, consider installing a transfer pump with a momentary switch. This allows you to transfer fuel between the tanks and provides the option to shut off the fuel flow in case of a leak. A transfer pump adds an extra layer of protection and control, reducing the risk of leaks during refuelling or extended use.
By following these instructions and tips, you can significantly reduce the chances of leaks when connecting a second diesel fuel tank. Remember to always consult with professionals or experts if you are unsure about any aspect of the installation process.
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Using a Y connector
Connecting two diesel fuel tanks using a Y-connector is a viable option, but there are some important considerations to keep in mind. This method involves joining the supply lines from both tanks with a Y-connector, as well as the return and vent lines. This design allows for equilibrium between the tanks, maintaining the same fuel level in both.
One advantage of using a Y-connector is that it simplifies the plumbing process by eliminating the need for additional pumps or complex switching mechanisms. It provides a direct connection between the two tanks, ensuring a constant fuel supply without the need for manual intervention.
However, one challenge to address is fuel level monitoring. The dash gauge will typically only indicate the fuel level in the original tank, showing a higher volume due to the additional fuel in the second tank. To overcome this, you may need to install a manual dual-port valve and an OEM tank switch to accurately monitor the fuel levels in both tanks.
Additionally, when using a Y-connector, it is crucial to consider the potential for fuel overflow when parking on a side slope. To prevent this, you can employ a dual-circuit ball valve or similar solutions to ensure that fuel does not drain from the higher tank into the lower one, causing an overflow.
Overall, using a Y-connector to connect a second diesel fuel tank offers a straightforward approach, but it requires careful consideration of fuel management and potential overflow issues to ensure a safe and effective implementation.
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Using a fuel selector valve
Connecting a second diesel fuel tank can be done in a few different ways. One way is to use a fuel selector valve, which allows you to run two separate fuel tanks and draw fuel from only one tank at a time. This is a good option if you want to be able to switch between the two tanks easily.
The fuel selector valve is located between the fuel pump and the fuel tank. It has a simple toggle or rocker switch that allows you to choose which tank to draw fuel from. You would need to run one fuel line from each tank to the valve and then a line from the valve to your engine. This setup is designed for vehicles with one main tank and one auxiliary tank. It is important to note that this type of valve is not suitable for systems that use in-tank fuel pumps or pumps located between the tanks and valve. It is also not suitable for marine applications.
There are a few different types of fuel selector valves available on the market, such as the Dual Tank Switching Valve Selector by SMP/Standard Motor Product APSG, which has 3 ports and can be purchased on Amazon. Another option is the Groco FV-6-5038 marine valve, which has 6 ports and can switch the return lines as well. This valve can be mounted under the cab of the vehicle, with the lever accessible through the floor.
When installing a fuel selector valve, it is important to be careful when taking it apart as some valves have a rubber diaphragm that can become damaged. Additionally, it is worth noting that if the selector valve is leaking internally, it can cause issues with fuel pressure and may need to be replaced. Regular maintenance and inspections can help ensure that the valve is functioning properly and prevent potential issues.
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Frequently asked questions
There are several ways to connect a second diesel fuel tank. You can either use a T-connection or Y-connection to join the supply lines from both tanks. You can also use a transfer pump and a momentary switch to connect the tanks.
Using a transfer pump and momentary switch allows you to transfer fuel from one tank to another as needed, rather than both tanks filling at the same time.
Using a T-connection or Y-connection creates a single larger fuel supply by joining the supply lines from both tanks. This option may be simpler and more cost-effective.
You will need some combination of the following parts: a fuel selector valve, connector harness, toggle switch, Y-connector or T-connector, hose, second fuel gauge, and a valve to prevent the engine from sucking air.
You should research the legalities of having a second fuel tank, as it may be illegal due to the fire hazard from possible leaks. You should also be cautious of the potential for fuel leaks and the snag points that may occur when going through rough terrain.
