Sylvie Willis
Dual fuel tanks are an appealing option for those seeking to extend their vehicle's range. However, there are several considerations to make when installing and using dual fuel tanks. This includes the plumbing design, which impacts the refueling process and fuel level equilibrium. For instance, connecting the tanks with a Y connector can maintain fuel level balance, but refueling requires filling both tanks simultaneously to avoid issues with fuel equalization. Additionally, the inclusion of valves, sumps, and pumps can impact the functionality and safety of the system.
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What You'll Learn
Using a Y connector to join supply and return lines
When hooking up dual fuel tanks, one setup option is to use a Y connector to join the supply and return lines. This method can be used to achieve equilibrium between the two tanks, ensuring the fuel level stays the same on both sides.
To do this, the supply lines from both tanks are connected with a Y connector, as are the return lines. This setup allows fuel to be drawn from both tanks simultaneously, maintaining equal fuel levels. However, it is important to consider that during refuelling, fuel must be added to both tanks to maintain equilibrium. Failing to do so may result in an uneven fuel distribution and potential issues with the fuel gauge.
One user suggests adding a tube between the two tanks at their lowest level to ensure equal fuel levels in both tanks. However, this can create a potential snag point when navigating rough terrain. Another consideration is the inclusion of a sump or a straw in each tank to aid in pressure delivery to the fuel pump.
Additionally, a check valve may be necessary on the smaller tank to prevent air from being sucked into the engine's fuel line through the Y connector. This setup allows for a continuous fuel supply without the need for switching valves.
Using a Y connector to join the supply and return lines offers a straightforward approach to dual fuel tank plumbing, providing a balanced fuel distribution between the tanks.
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Installing a manual dual port valve
Selecting the Valve
Choose a suitable dual-port valve for your specific vehicle and application. For example, the Groco FV-6-5038 bronze 6-port marine valve is recommended for switching between two tanks and can also switch the return lines. Ensure that the valve you select is compatible with your vehicle's fuel system and meets any necessary safety standards.
Mounting the Valve
Decide on a suitable mounting location for the valve. Some users recommend mounting the valve under the cab, with the lever passing through a rubber grommet in the cab floor. This provides easy access to the lever without needing to get under the vehicle. However, you may need to consider other mounting options depending on your vehicle's configuration and your personal preferences.
Connecting the Valve
Connect the valve between the fuel pump and the fuel tank(s). Ensure that you follow the manufacturer's instructions and any relevant guidelines for your vehicle's fuel system. Pay close attention to any warnings or restrictions, such as not using the valve with vehicles that have fuel return lines or in marine applications.
Adding the OEM Tank Switch
After installing the valve, you will need to add an OEM tank switch to control the dash gauge. This will allow you to monitor the fuel level in the tanks accurately.
Testing and Verification
Once the valve is installed, test the system thoroughly to ensure it functions correctly and safely. Verify that you can switch between the tanks as intended and that the fuel gauge accurately reflects the fuel level in the selected tank.
Remember to consult a professional or a mechanic if you have any doubts or concerns during the installation process. Safety should always be a top priority when working with fuel systems.
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Ensuring fuel equilibrium in both tanks
However, it is important to note that refuelling can be a potential challenge with this system. To maintain equilibrium, both tanks must be refuelled simultaneously. If only one tank is refuelled, the fuel will not equalize between the tanks. Therefore, it is essential to have a system in place that allows for simultaneous refuelling of both tanks.
One solution to this challenge is to add a tube between the two tanks at their lowest level. This tube ensures that the fuel level remains equal in both tanks, even during refuelling. However, this setup may introduce a potential snag point when navigating rough terrain.
Another approach to maintaining fuel equilibrium is to use a dual port valve to switch between the two tanks. This setup involves installing a manual dual port valve, such as the Groco FV-6-5038 bronze 6-port marine valve, which allows for switching between the tanks and their return lines. By mounting this valve in an accessible location, such as under the cab, you can easily switch between the tanks as needed.
Additionally, consider installing a fuel transfer pump to facilitate fuel movement between the tanks. This setup can include a fuel pump switched in the cab, allowing for the transfer of fuel from the auxiliary tank to the main tank when necessary. This ensures that both tanks can be maintained at similar fuel levels, providing a more consistent fuel supply.
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Avoiding overfilling with a return line
When hooking up dual fuel tanks, it is important to consider how to avoid overfilling with a return line. Overfilling your gas tank can have serious consequences, including environmental damage and safety hazards. Here are some ways to avoid overfilling:
Firstly, consider using a manual dual-port valve to switch between the two tanks. Groco offers a FV-6-5038 bronze 6-port marine valve that can be used for this purpose. This valve can be mounted under the cab, with the lever accessible through a rubber grommet in the cab floor. This option allows you to switch between tanks and control the flow of fuel, helping to prevent overfilling.
Another option is to install an equalization line between the two tanks. This line will ensure that the fuel level stays the same in both tanks, reducing the risk of overfilling one tank while drawing fuel from the other. You can also add a second fuel gauge and an electric pump to transfer fuel between the tanks, allowing you to maintain equilibrium.
Additionally, consider using a fuel injection system with a return line. This system can include a solenoid that diverts the fuel to the tank you are drawing from, preventing overfilling. You can also connect the return line to one tank and pump the fuel to the other tank when it is full, although this option may not be ideal.
Finally, pay attention to the fuel level and fill up only to the recommended level. Most gas station pumps have a valve that automatically shuts off when the gas tank is full, helping to prevent overfilling. By combining these measures, you can effectively avoid overfilling your dual fuel tanks and ensure a safer and more efficient fuel system.
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Using a fuel pump to transfer fuel
When hooking up dual fuel tanks, one option is to use a fuel pump to transfer fuel between the two tanks. This method is useful when refuelling, as it ensures that both tanks maintain an equal amount of fuel.
To set up this system, you can install a fuel pump between the two tanks. This pump can be activated manually or automatically. When the fuel level in one tank is lower than the other, the pump can be turned on to transfer fuel from the fuller tank to the emptier one. This process will continue until both tanks reach the same fuel level.
For example, one user with a 2005 IHC 4400 DT466 with dual fuel tanks encountered an issue where the electric fuel pump between the tanks would not pump fuel. A technician suggested checking if the pump had power and if it was turned on, as some vehicles require the engine to be running for at least five minutes to activate the pump.
Another user with a 1995 Toyota FZJ80 Land Cruiser wanted to install a dual-fuel tank setup with a fuel pump to transfer fuel from the auxiliary tank to the main tank. They were concerned about the accuracy of the fuel gauge during the transfer process. A suggested solution was to use the auxiliary tank's fuel sender to wire in a gauge or a low-pressure fuel gauge to monitor the line pressure during the transfer.
It is important to note that some users prefer to keep the two tanks separate and use a transfer pump with a momentary switch to control the flow of fuel between them. This setup provides more control over the fuel levels in each tank and can be useful in certain situations, such as when one tank is almost empty and you want to reserve it for emergency use.
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Frequently asked questions
There are several ways to hook up dual fuel tanks. One way is to use a Y connector to join the supply lines, return lines, and vent lines between the two tanks. Another way is to add a manual dual-port valve to switch between the two tanks.
One thing to consider is how to maintain equal fuel levels in both tanks. One way to do this is to add a tube between the two tanks at the lowest level. Another thing to consider is the need for a check valve on the smaller tank to prevent air from being sucked into the engine's fuel line.
One potential problem is that during refueling, you will need to add fuel to both tanks. If you only fill one tank, the fuel will not equalize between the two tanks. Another potential problem is that having another pump increases the risk of leaks, which could create a fire hazard.
