Regan Brown
There are various methods to connect two diesel fuel tanks together, depending on the vehicle and the desired outcome. Some people opt to use a manual dual-port valve to switch between the two tanks, while others suggest using a transfer pump and momentary switch. Another method is to use a Y connector to join the supply lines from both tanks, as well as the return and vent lines, allowing equilibrium between the tanks. However, it's important to note that some of these methods may be illegal for gas-powered vehicles, and there are also safety concerns to consider, such as the potential for fuel to drain from one tank into another and cause an overflow.
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What You'll Learn
Using a Y connector to join supply, return and vent lines
Connecting two diesel fuel tanks together can be done in several ways, depending on the specific vehicle and requirements. One method is to use a Y connector to join the supply, return, and vent lines between the two tanks. This approach offers a simple and effective way to link the tanks and establish equilibrium, ensuring the fuel level remains the same on both sides.
To implement this method, you can follow these steps:
- Obtain a Y connector that matches the size and type of your fuel lines. Ensure it is suitable for diesel fuel and compatible with your vehicle's fuel system.
- Install the Y connector by joining the supply lines from both tanks. This will create a continuous fuel supply line between the tanks.
- Similarly, use additional Y connectors to join the return lines from both tanks. This will allow for the circulation of fuel between the tanks.
- Connect the vent lines between the two tanks. This will enable the release of air and maintain the appropriate pressure within the fuel system.
- Ensure that all connections are secure and properly sealed to prevent leaks.
By using Y connectors for the supply, return, and vent lines, you create a continuous fuel system that draws from and supplies fuel to both tanks simultaneously. This setup can help maintain the same fuel level in both tanks and provide a more unified fuel supply for your vehicle. However, it is important to consider the specific requirements and configurations of your vehicle's fuel system when implementing this or any other method of connecting dual diesel fuel tanks.
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Using a manual dual port valve to switch between tanks
One way to connect two diesel fuel tanks together is by using a manual dual port valve to switch between the two tanks. This method can be used as an alternative to the FSV when it stops working.
A dual port valve can be used to switch between two tanks, allowing you to run two separate fuel tanks and draw from one tank at a time. You can use a common toggle or rocker switch for this. You would need to run one fuel line from each tank to the valve and a line from the valve to your engine.
One user on SteelSoldiers recommended installing a Groco FV-6-5038 bronze 6-port marine valve to switch between the two tanks. They mounted the valve under the cab with the lever through a rubber grommet in the cab floor. They also added the OEM tank switch to switch the dash gauge.
Another user on Oilburners.net recommended using brass valves with three hose barbs. One valve is for the fuel supply, and the other is for the fuel return. You would turn both to the front or both to the rear.
It is important to note that the hose can only bend so much before it will kink. You will need to play with the hose to get nice gradual bends and ensure it is running along a direct route, staying clear of pinch points and anything sharp.
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Using a transfer pump and momentary switch
Connecting two diesel fuel tanks together can be done in several ways, one of which is by using a transfer pump and momentary switch. This method allows you to transfer fuel from one tank to another and maintain control over the fuel levels in each tank. Here is a step-by-step guide on how to connect two diesel fuel tanks using this method:
Step 1: Install the Transfer Pump
Install a transfer pump between the two diesel fuel tanks. This pump will be responsible for moving the fuel from one tank to the other. You can choose between an electric or manual transfer pump, depending on your preference and the specific use case. Ensure that the pump is securely mounted and connected to a power source if it is electric.
Step 2: Connect the Fuel Lines
Connect the inlet and outlet lines of the transfer pump to the respective diesel fuel tanks. Use fuel-resistant hoses and ensure that all connections are secure and tight to prevent leaks. The inlet line will draw fuel from one tank, and the outlet line will transfer it to the other.
Step 3: Install the Momentary Switch
Install a momentary switch that will control the operation of the transfer pump. This switch will allow you to turn the pump on and off as needed. Ensure that the switch is easily accessible and clearly labelled, so you can control the fuel transfer process.
Step 4: Test the Setup
Before using the connected diesel fuel tanks, test the setup to ensure it works correctly. Start by filling one tank with diesel fuel and ensuring that the other tank is empty. Turn on the transfer pump using the momentary switch and observe the fuel level in each tank. The fuel level in the first tank should decrease, while the second tank should start filling up.
Step 5: Monitor Fuel Levels
It is important to monitor the fuel levels in both tanks during the transfer process. Ensure that the tanks do not overflow, as this can be dangerous and cause spills. You can install fuel gauges or use a clear container to visually inspect the fuel levels.
Step 6: Adjust as Needed
Depending on your specific use case and the size of your diesel fuel tanks, you may need to adjust the transfer pump's flow rate or the timing of the momentary switch operation. Test the setup with different fuel levels and adjust the settings until you find the optimal configuration for your needs.
By following these steps, you can effectively connect two diesel fuel tanks together using a transfer pump and momentary switch. This setup provides you with control over the fuel transfer process and allows you to utilise the fuel capacity of both tanks efficiently.
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Using a single fuel fill hose and connection
Connecting two diesel fuel tanks with a single fuel fill hose and connection is a feasible option, but it's important to carefully consider the design and implementation to ensure safety and functionality. Here's a step-by-step guide on how to achieve this:
Step 1: Sourcing the Tanks
Start by sourcing two diesel fuel tanks of similar or identical capacities. It is essential to use tanks with compatible fittings and components to ensure a proper seal and avoid leaks.
Step 2: Mounting the Tanks
Mount the tanks securely in your desired location, ensuring they are stable and fixed firmly in place. This provides a solid foundation for the fuel system and reduces the risk of damage or disconnection during use.
Step 3: Installing the Fuel Fill Hose
Acquire a fuel fill hose that is compatible with diesel fuel and rated for your specific application. The hose should be long enough to reach between the two tanks comfortably. Connect one end of the hose to the fuel filler pipe of one of the tanks. This will be the primary tank that you fill up directly.
Step 4: Adding a "Tee" or "Y" Connector
Cut the fuel filler pipe of the primary tank and install a "Tee" or "Y" connector. This connector will allow fuel to flow into both tanks simultaneously when filling up. Ensure that the connector is securely attached to prevent leaks.
Step 5: Connecting the Tanks
Use a hose to connect the two tanks at the bottom, allowing fuel to flow in and out between them. This ensures that the fuel level remains equal in both tanks. Additionally, connect a hose at the top for air to move in and out, facilitating smooth fuel transfer.
Step 6: Ventilation and Equalization
Ensure that both tanks have proper ventilation to prevent pressure build-up. Connect the vent lines between the two tanks to maintain equilibrium and allow the fuel level to stay the same on both sides. This step is crucial for the proper functioning of the dual-tank system.
Step 7: Testing and Safety
Before using the connected diesel fuel tanks, thoroughly inspect all connections for leaks. Test the system by filling up the tanks and checking for any signs of fuel leakage or abnormal behaviour. Ensure that the fuel gauge accurately reflects the combined fuel level of both tanks.
By following these steps, you can successfully connect two diesel fuel tanks together using a single fuel fill hose and connection. Remember to adhere to safety guidelines and consult experts or mechanics if you have any doubts or concerns during the installation process.
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Using a T in the factory fuel lines
Using a T-connector in the factory fuel lines is a possible way to connect two diesel fuel tanks. This method involves installing a T-shaped connector in the fuel lines that supply the tanks, allowing fuel to flow between the two tanks. This setup can be used to create a single fuel supply from the combined capacity of both tanks.
However, there are some potential issues with this method. One problem is that the fuel gauge may only work for one of the tanks, making it difficult to determine the fuel level in the other tank. Additionally, if one tank runs out of fuel before the other, it can start sucking air into the fuel lines, causing problems with the fuel system.
To address these issues, some people suggest installing additional equipment, such as manual dual-port valves, OEM tank switches, or fuel pumps, to control and monitor the fuel level in each tank more effectively. Others recommend using a gravity feed system, where the tanks are connected at the bottom for fuel flow and at the top for air movement, eliminating the need for secondary or transfer pumps.
It is important to carefully consider the potential complexities and failure points when connecting two diesel fuel tanks. While using a T-connector in the factory fuel lines can work, it may require additional modifications and maintenance to ensure a reliable and safe fuel system.
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Frequently asked questions
It is legal to connect two diesel fuel tanks together. Older 18-wheelers used to have two tanks with a crossover. However, it is illegal for gas-powered vehicles to have this setup.
There are a few ways to connect two diesel fuel tanks. One way is to use a Y connector to join the supply, return, and vent lines between the two tanks. This will allow for equilibrium, keeping the fuel level the same in both tanks. Another way is to add a manual dual-port valve to switch between the two tanks.
One potential issue is that if one tank runs out of fuel before the other, it will start sucking air into the fuel lines. Another issue is that if the hose breaks, both tanks could drain onto the ground.
