Sylvie Willis
Installing an auxiliary diesel fuel tank in your pickup truck can be a great way to extend your driving capability and provide peace of mind when embarking on extended trips. Before you begin the installation process, it is important to ensure you have a spacious and safe working environment. Once you have sufficient space, remove any items from the bed of the truck, such as a bed mat. The next step is to carefully lift the auxiliary diesel fuel tank into the bed of your truck, taking care not to scratch the truck's finish. Now, you can mark the holes where the tank will be attached to the truck bed, using a brightly coloured marking tool to avoid drilling mistakes. After marking the locations, remove the tank and drill the holes, starting with a small bit before moving on to a larger one. Finally, you can secure the tank in place using bolts, nuts, and washers, and, if necessary, connect the fuel line by punching or cutting a hole in the rubber plug near the stake pocket support posts.
Installation characteristics of an auxiliary diesel fuel tank
| Characteristics | Values |
|---|---|
| Space | Ensure there is plenty of space to work in to avoid accidents and injuries |
| Items | Remove any items inside the bed of the truck |
| Weight | Not very heavy but an extra set of hands will help with lifting the tank |
| Placement | Set up the placement of the tank before drilling holes |
| Marking | Use a brightly colored marking tool to mark the holes where the tank will be attached to the bed of the truck |
| Drilling | First drill the holes with a small bit to act as a "pilot hole" for the larger bit |
| Rubber plugs | Remove rubber plugs at the bottom of the stake pocket support posts to gain access to the bottom side of the truck bed |
| Rubber fuel line | Cut a hole in the center of the rubber plug to insert the rubber fuel line |
| Bolts, nuts and washers | Use these to fasten the fuel tank in position |
| Fuel filter | Prime the fuel filter before installing it |
| Gravity feed | Fill both factory and auxiliary tank; as the factory tank gets used, fuel from the auxiliary tank replaces the fuel |
| Pump | The driver must pay attention to the main fuel gauge and manually turn the pump off to avoid losing fuel |
| Enclosure | Enclose the fuel cell in a second enclosure, or use bladder and foam systems |
| Rubber mat | Install a rubber mat between the battery pack and the auxiliary tank |
| Fuel Shotz installation kit | Can be installed in less than an hour, connecting the auxiliary tank to the factory tank via the factory filler |
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What You'll Learn
- Ensure you have ample space to work, preventing accidents and injuries
- Mark the holes for installation using a brightly coloured marking tool
- Use an inline fuel filter and prime it before installing
- Consider a gravity feed system to fill both factory and auxiliary tanks
- Use a Fuel Shotz installation kit for a quick and easy setup
Ensure you have ample space to work, preventing accidents and injuries
When installing an auxiliary diesel fuel tank, ensuring you have ample space to work is crucial for preventing accidents and injuries. Here are some detailed steps to achieve this:
First, make sure you have a spacious work area around your truck. Most accidents occur when people are cramped for space and cannot move freely. Remove any items inside the bed of the truck, such as a bed mat, to create a clear and safe workspace.
If you need to lift the truck to access the undercarriage during installation, use a jack that is rated to safely lift your vehicle. This will provide you with the necessary space and access while also ensuring stability and safety.
When handling the auxiliary diesel fuel tank, having an extra set of hands can be beneficial. Not only will it lighten the load, but it can also help prevent any scrapes or scratches to your truck's finish. Place the auxiliary diesel fuel tank in the desired location, ensuring it is secure and stable before proceeding.
Before marking the holes for installation, double-check that you have the correct placement. This will reduce the risk of drilling errors and potential damage to your vehicle. Use a brightly colored marking tool, such as a wax pen or chalk, to clearly indicate the mounting locations.
By following these steps, you will have ample space to work and significantly reduce the chances of accidents and injuries during the installation of your auxiliary diesel fuel tank. Remember, taking the time to prepare your workspace and following safety precautions will make the installation process much smoother and safer.
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Mark the holes for installation using a brightly coloured marking tool
Once you have ensured you have enough space to work and removed any items inside the bed of the truck, you can start the installation process. Place the auxiliary diesel fuel tank in the location where it will be installed. All tanks come with mounting tabs located either on the bottom edges or, in the case of taller tanks, on the bottom and on the taller back edges. With the tank properly located, you need to visibly mark the holes where you’ll attach the fuel tank to the bed of the pickup.
Use a brightly coloured marking tool such as a wax pen or chalk to mark the mounting locations. This will help you avoid drilling the wrong hole. After marking, remove the auxiliary diesel fuel tank from the pickup bed. You can now centre punch the locations of the holes to prevent the drill bit from straying from the desired location.
Drill the holes with a small bit first to create a "pilot hole" for the larger bit. This will ensure that you don't accidentally drill into the truck bed. Now that the holes are drilled, you can proceed to fasten the fuel tank in position using bolts, nuts, and washers. It is helpful to have an extra set of hands to hold the nuts or bolts in place as you tighten them from either the bottom or top of the auxiliary truck bed fuel tank.
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Use an inline fuel filter and prime it before installing
When installing an auxiliary diesel fuel tank, it is important to consider using an inline fuel filter. This can help to ensure the fuel system remains free of contaminants and that the engine runs smoothly. Inline fuel filters are especially useful if you are using older diesel fuel or if your fuel supply may be contaminated.
Before installing the inline fuel filter, it is important to prime it. Priming the filter simply means filling it with diesel fuel. This can be done by removing the filter and pouring diesel fuel into it. Some filters may have specific priming procedures, so be sure to check the manufacturer's instructions. By priming the filter beforehand, you can help ensure that the fuel system is ready to use once the filter is installed.
It is worth noting that some sources suggest that pre-filling a fuel filter is not necessary and may even be detrimental. They argue that modern fuel systems are designed to fill the filter automatically and that pre-filling can introduce contaminants into the system. However, others argue that pre-filling can save time and effort, especially if you have an older vehicle or a system without a lift pump.
When it comes to the installation process, it is important to follow the manufacturer's instructions for your specific filter and vehicle. Make sure you have a clear and safe workspace and consider having an extra set of hands to help with the installation. Mark the holes for the filter and tank carefully to avoid any mistakes. By taking your time and following the correct procedures, you can ensure a safe and successful installation of your auxiliary diesel fuel tank and inline fuel filter.
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Consider a gravity feed system to fill both factory and auxiliary tanks
When installing an auxiliary diesel fuel tank, it is important to consider a gravity feed system to fill both the factory and auxiliary tanks. This system can be a great way to ensure your engine always has enough fuel and can help extend your driving capability, especially on long hauls or trips.
A gravity feed system allows fuel to flow from the auxiliary tank to the factory tank, ensuring a constant feed to the engine. This can be a slow process, but as long as the check valve is functioning, it will prevent the factory tank from overflowing. The check valve is an important component of a gravity feed system as it regulates the fuel transfer, cutting off the flow if the fuel level gets too high.
To set up a gravity feed system, you will need to consider the placement of the auxiliary tank and the method of fuel transfer. The auxiliary tank should be placed higher than the factory tank to utilise gravity. You can then choose to transfer the fuel through a simple gravity feed system or use a pump to speed up the process. If you opt for a gravity-only system, ensure you have the appropriate valves, such as shut-off, vent, and overflow valves, to regulate the fuel transfer and prevent leaks.
When installing a gravity feed system, it is crucial to follow the manufacturer's instructions and adhere to any relevant regulations. Additionally, consider seeking professional assistance if you are unsure about any part of the installation process.
By implementing a gravity feed system, you can ensure that your engine has a constant supply of fuel, providing peace of mind and extended driving capabilities. However, always be mindful of the regulations and safety precautions to ensure a safe and effective installation.
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Use a Fuel Shotz installation kit for a quick and easy setup
If you're looking for a quick and easy way to install an auxiliary diesel fuel tank, the Fuel Shotz installation kit is a great option. This kit can be installed in less than an hour and doesn't require any wire splicing or switches, making it a straightforward process even for those who aren't mechanically inclined.
The Fuel Shotz kit is designed to connect your auxiliary fuel tank to the factory fuel tank using the factory fill tube. It's important to note that the ATI Fuel Shotz kit is specifically made to work with ATI Auxiliary Fuel Tanks, so you'll need to ensure compatibility before purchasing. Once you've confirmed the correct make and model of your truck, you can proceed with the installation.
The kit comes with detailed instructions that should be followed carefully. Start by ensuring you have enough space to work and removing any items from the bed of your truck. The auxiliary tank can then be placed into position, and you can use the provided bolts, nuts, and washers to secure it in place. An extra set of hands can be helpful at this stage.
One of the benefits of the Fuel Shotz kit is that it includes everything you need for a secure installation. The system has rollover protection on both the tank and the factory fill neck adapter, giving you peace of mind on your journeys. Additionally, the kit meets DOT requirements for diesel auxiliary fuel tanks, ensuring its legality.
With the Fuel Shotz installation kit, you can quickly and conveniently install an auxiliary diesel fuel tank, providing you with extended driving capability and the assurance of having extra fuel during emergencies or long trips.
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Frequently asked questions
Here is a list of steps to help you install an auxiliary diesel fuel tank:
- Ensure that you have ample space to work in and remove any objects inside the truck bed.
- Place the auxiliary diesel fuel tank in the desired location.
- Mark the holes where you will install the tank using a brightly coloured marking tool.
- Remove the tank and drill holes with a small bit, then use a larger bit for the final hole.
- Place the tank back into position and fasten it using bolts, nuts, and washers.
- If you are using an inline fuel filter, prime it before installing.
Here are some tips to ensure a safe and effective installation:
- Have an extra set of hands to help lift and position the tank.
- Use a jack to safely lift the truck and gain access to the underside of the truck bed.
- Consider the orientation of the valve to ensure proper function and prevent fuel loss.
- Install cushion strips between the tank and bed to prevent scratches and damage.
There are two main options for transferring fuel: gravity feed and pump-based systems. With gravity feed, both tanks are filled, and fuel is transferred from the auxiliary tank as the main tank gets used. With a pump-based system, the driver flips a switch to transfer fuel. It is important to manually control fuel transfer and pay attention to the main fuel gauge to avoid overfilling and fuel loss.
