Rajan Wilcox
Having dual fuel tanks with one pump is possible, and there are several ways to go about it. One method is to use a Y connector to join the supply, return, and vent lines of both tanks, allowing for equilibrium and maintaining the same fuel level in both tanks. Another approach is to use a transfer pump and a momentary switch to connect the tanks separately. A third option is to use a dual-circuit ball valve to switch both the supply and return simultaneously. Additionally, some vehicles with EFI systems may require a return-style fuel pump and regulator to ensure fuel returns to the same tank. While a single pump is less expensive and easier to install, having two pumps provides redundancy in the unlikely event of pump failure.
| Characteristics | Values |
|---|---|
| Fuel Tank Setup | Dual fuel tanks with one pump |
| Fuel Pump Type | Return-style fuel pump |
| Fuel Regulator | Return fuel to the same tank |
| Fuel Source Selection | Motorized valve to switch fuel source |
| Fuel Line Connection | Supply lines joined with a Y connector |
| Return Line Connection | Return lines joined with a Y connector |
| Vent Line Connection | Connected between the two tanks |
| Fuel Level Equilibrium | Maintain equal fuel level in both tanks |
| Fuel Gauge Indication | Indicates total fuel level across both tanks |
| Refueling Consideration | Fill up both tanks to maintain equilibrium |
| Fuel Transfer | Use a transfer pump or gravity feed |
| Fuel Equalization | Use an equalizing line at the bottom of the tanks |
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What You'll Learn
EFI fuel pump kits for dual-tank vehicles
Upgrading a vehicle with two fuel tanks to an electronic fuel injection (EFI) system presents a unique challenge. A fuel source must be selected, and the return-style fuel regulator must return the fuel to the same tank. Additionally, if the vehicle has a shared fuel level gauge, the fuel source, return, and level sender must be switched simultaneously. This is where EFI fuel pump kits for dual-tank vehicles come in.
Another option for dual-tank vehicles is to use an in-tank fuel pump module, such as the PA-Series offered by Tanks Inc. This module can be used to retrofit an internal fuel pump into an existing gas tank, eliminating common issues with external fuel pumps such as vapor lock and cavitation. The PA-Series fuel pump assemblies feature a female 1/4" NPT fitting on the top plate, allowing for proper venting during conversion to fuel injection. It is important to note that these kits do not include fuel pressure regulators, and assembly requires a minimum tank depth of 6 inches.
When considering an EFI fuel pump kit for a dual-tank vehicle, it is important to evaluate the specific needs of the vehicle and the fuel system. The location of the fuel tanks, the presence of a shared fuel level gauge, and the desired level of redundancy or reliability can all impact the decision between a single or dual-pump kit. Additionally, the compatibility of the fuel pump with the vehicle's fuel injection system and the availability of necessary components, such as fuel pressure regulators, should be carefully considered.
Overall, EFI fuel pump kits for dual-tank vehicles offer a comprehensive solution for upgrading to an EFI system in vehicles with two fuel tanks. By providing the necessary components, including fuel pumps, motorized valves, and EFI-rated hoses, these kits simplify the complex process of switching fuel sources and returns in dual-tank configurations. With careful consideration of the vehicle's specific requirements, these kits can ensure a successful and reliable EFI system upgrade.
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The benefits of two pumps
While a single pump is adequate for most purposes, there are several benefits to having two fuel pumps. Firstly, in the unlikely event of pump failure, having two pumps ensures that you can always pull fuel from the second tank. This provides a level of redundancy and peace of mind, especially if you are travelling long distances or in remote areas where access to fuel pumps may be limited.
Another advantage of dual pumps is increased fuel flow. When two pumps are used in parallel, the total output is doubled compared to a single pump at the same pressure. This setup is beneficial for applications requiring a high fuel flow rate, such as high-performance engines or vehicles operating under boosted conditions. By using two pumps in series, the pressure capabilities of the system can also be increased, allowing for higher-pressure fuel delivery to the engine, which can be beneficial for certain performance or efficiency goals.
Additionally, with two pumps, you have the flexibility to choose different pump sizes. This can be advantageous if you are looking to optimise your fuel system for specific requirements. For example, a smaller pump can be used to feed a larger one, allowing for a more customised setup that balances pressure and flow rate according to your needs.
Finally, dual pumps can provide a more even distribution of fuel, especially in vehicles with multiple fuel tanks. This can help ensure that the fuel level in each tank remains balanced, reducing the risk of uneven weight distribution and improving the overall stability and handling of the vehicle.
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Using a Y connector to join supply and return lines
When using a Y connector to join supply and return lines in a dual fuel tank system with a single pump, there are several considerations and potential challenges to keep in mind. Firstly, it is important to ensure that the fuel levels in both tanks remain equal to maintain equilibrium. This can be achieved by installing a tube or connecting hose at the lowest level of the tanks, allowing the fuel to equalize through gravity. However, this setup may present challenges when navigating rough terrain, as the connecting tube can become a potential snag point.
Additionally, when using a Y connector, it is crucial to address the issue of airlocks and air leaks. If one tank runs dry, it will start sucking air, rendering the remaining fuel in the other tank unusable. To mitigate this issue, it is essential to ensure that all air is removed from the lines and that there are no tiny air leaks, as this can cause the generator to stop prematurely.
Furthermore, when using a Y connector, it is important to consider the positioning and installation of the connector itself. The connector should be securely attached to the supply lines of both tanks, allowing for a smooth and uninterrupted fuel flow. It is also worth noting that the dash gauge will still indicate the same fuel level, but it will represent the total combined fuel volume in both tanks.
When employing a Y connector, it is advisable to use a dual circuit ball valve or a manual dual-port valve to switch between the two tanks. This ensures that both the supply and return lines are switched simultaneously, providing better control over the fuel system. Additionally, it is recommended to have a momentary switch or a motorized valve to facilitate the transfer of fuel between the tanks.
Overall, using a Y connector to join the supply and return lines in a dual fuel tank system offers a viable option for maintaining fuel equilibrium and ensuring a consistent fuel supply. However, careful consideration must be given to potential challenges, such as airlocks and snag points, to ensure a safe and effective implementation.
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Using a dual circuit ball valve
To set up this system, you can run one fuel line from each tank to the valve and another line from the valve to the engine. This configuration allows you to draw fuel from either tank, providing flexibility and redundancy. Additionally, a dual circuit ball valve typically has an off position, which can serve as a passive anti-theft measure.
When considering the mounting location for the valve, it is recommended to place it under the frame, making it easily accessible without having to get under the vehicle. This setup can be further enhanced by incorporating gravity feed into the system, allowing fuel to drain from the auxiliary tank into the main tank.
A dual circuit ball valve is a reliable option for dual fuel tank systems, offering both convenience and security. It is a straightforward solution that can be adapted to various vehicle configurations.
It is worth noting that there are alternative methods for connecting dual fuel tanks, such as using a Y connector to join the supply and return lines, but the dual circuit ball valve method provides a more controlled and efficient approach to managing fuel transfer between the tanks.
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The challenges of upgrading to EFI
Upgrading to an EFI fuel system can present several challenges, especially when dealing with dual fuel tanks. Here are some of the key challenges to consider:
Firstly, a fuel source selection process must be implemented, and the return-style fuel regulator must direct fuel back to the same tank. This can be a complex process, and it is a challenge unique to dual-tank setups. Additionally, most vehicles with dual fuel tanks have a shared fuel level gauge, which can further complicate the upgrade process.
EFI systems also have strict rules for internal bootable device organization and specific requirements for boot entries. This can cause issues when migrating from a non-EFI system, as the OS may fail to boot. This is a known issue when upgrading to Windows 8, for example, where incorrect links in UEFI can prevent the OS from booting.
Upgrading EFI firmware can also be challenging, as seen with Apple MacBook Pros. In some cases, the firmware update process may be skipped during a fresh install. Workarounds include connecting to the original HDD via USB and upgrading to the new OS on that disk before reconnecting the SSD and running the upgrade again.
Finally, while a single pump EFI system is less expensive and easier to install, a dual pump system offers redundancy in the unlikely event of pump failure. This is an important consideration when weighing the challenges and benefits of upgrading to EFI with dual fuel tanks.
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Frequently asked questions
A dual fuel tank system involves two fuel tanks in a vehicle, which can be plumbed together to create one larger fuel supply.
The main benefit of a dual fuel tank system is the increased fuel capacity, which can provide a longer range for vehicles. Additionally, in the unlikely event of a pump failure, having two pumps means you can always pull from the second tank.
One drawback is the inconvenience of refuelling, as both tanks need to be filled up separately. This can be time-consuming and may require manoeuvring the vehicle to access both tanks.
It is recommended to use a dual circuit ball valve or a dual port valve to switch between the two tanks. Additionally, consider using a transfer pump and a momentary switch to transfer fuel between the tanks. For vehicles with a shared fuel level gauge, a second fuel gauge may be necessary.
