Ameer Randolph
Installing an auxiliary fuel tank in your vehicle can be a great way to extend your driving range and provide peace of mind in emergency situations. While the process may vary slightly depending on your vehicle's specific make and model, there are some general steps you can follow to ensure a proper and safe installation. It is important to plan the installation process carefully, ensuring you have sufficient space to work and taking precautions to avoid accidents or damage to your vehicle.
How to Install an Auxiliary Fuel Tank
| Characteristics | Values |
|---|---|
| Space | Ensure there is plenty of space to work in and around the vehicle. |
| Items | Remove any items inside the bed of the truck, e.g. a bed mat. |
| Weight | Auxiliary fuel tanks are usually lightweight, but an extra set of hands is helpful for installation. |
| Placement | Install the tank away from the sides, front, and back of the bed, with space on all four sides to prevent rubbing and damage. |
| Marking | Use a bright wax pen or chalk to mark the holes for drilling. |
| Drilling | Drill holes in the marked spots to attach the fuel tank to the bed of the pickup. |
| Rubber Plugs | Remove rubber plugs from the bottom of the stake pocket support posts to access the bottom side of the truck bed. |
| Rubber Fuel Line | Cut a hole in the center of the rubber plug, insert the rubber fuel line, and run it towards the factory fuel neck. |
| Bolts and Nuts | Place the auxiliary fuel tank in position and fasten it with bolts, nuts, and washers. |
| Fuel Filter | Prime the fuel filter before installation if using an inline filter. |
| Gravity Feed | Consider using a gravity feed system instead of a pump to transfer fuel from the auxiliary tank to the main tank. |
| Fuel Gauge | Install an in-cab gauge for the auxiliary tank. |
| Manual Valve | Install a manual valve to control the use of the auxiliary tank. |
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What You'll Learn
Ensure you have enough space to work safely
When installing an auxiliary fuel tank, ensuring adequate workspace is crucial for safety. Most accidents and injuries during installation occur due to cramped spaces that hinder free movement. Thus, before beginning the installation process, confirm that you have ample space to work comfortably and safely.
Clear the truck bed of any items, such as bed mats, that might obstruct your workspace. If you need to lift the truck to access the undercarriage during installation, use a jack with a high enough rating to safely lift the vehicle. Remember, for safety reasons, do not go under the vehicle when it is solely supported by the jack. Instead, use appropriately sized jack stands placed on flat sections of the vehicle's frame to provide stable support.
When positioning the auxiliary fuel tank, ensure it is not placed directly against the sides, front, or back of the truck bed. Leaving some space around all four sides of the tank is essential to prevent it from rubbing against the truck bed, which could potentially damage the tank. Additionally, consider the weight of the auxiliary fuel tank and its impact on weight distribution. A heavy tank can affect the truck's handling and towing capabilities, so proper installation and balancing are critical for safety.
Having an extra set of hands during the installation process can be beneficial. Not only will it lighten the load, but it can also help prevent any scrapes or scratches to the truck's finish. With these safety precautions in mind, you can ensure you have enough space to work safely when installing an auxiliary fuel tank.
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Mark the holes for installation
Once you have ensured you have enough space to work in and around your truck, you can begin the process of marking the holes for installation.
First, place the auxiliary diesel fuel tank in the location where it will be installed. It is important to ensure that the tank is not placed directly at the sides, front, or back of the bed, as this may cause the tank to rub against the truck bed and potentially cause damage. Instead, aim to have some space on all four sides of the tank.
Next, you will need to mark the holes where you will attach the fuel tank to the bed of your pickup. All tanks come with mounting tabs, which are usually located on the bottom edges. For taller tanks, there may also be mounting tabs on the taller back edges to prevent them from tipping over. Use a brightly coloured marking tool, such as a wax pen or chalk, to visibly mark these holes. This will help you avoid mistakenly drilling in the wrong place.
After marking the mounting locations, remove the auxiliary diesel fuel tank from the pickup bed. At this stage, you may wish to centre punch the locations of the holes to prevent the drill bit from straying.
Now you can begin drilling. First, drill the holes with a small bit to create a "pilot hole" for the larger bit. The final hole should be drilled with a bit that matches the bolts you have chosen to use. Before drilling, check the undercarriage of the truck bed to ensure there are no items underneath that you might accidentally drill into, such as the existing fuel tank.
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Place the tank and fasten it with bolts, nuts, and washers
Once you have found a good location for your auxiliary fuel tank, you can start the process of securing it in place. It is important to ensure that the tank is not placed directly against the sides, front, or back of the bed of your truck. This is to prevent the tank from rubbing against the truck bed and causing potential damage. It is also a good idea to have someone assist you with this process, as they can help to hold the nuts and bolts in place while you tighten them.
First, mark the holes where you will attach the tank to the bed of your truck. Use a brightly coloured marking tool, such as a wax pen or chalk, to clearly indicate the drilling spots. This will help to ensure that you don't accidentally drill in the wrong place.
Next, you will need to drill holes in the marked spots. Make sure that you have the correct size drill bit for the job and that you are wearing the appropriate safety gear, including eye protection and gloves.
Now, you can place the auxiliary fuel tank into position. Line up the holes in the tank with the holes you have drilled in the truck bed. Insert the bolts through the holes and secure them with nuts and washers on the other side. Tighten the bolts securely, but be careful not to over-tighten them as this could strip the threads or damage the tank.
Finally, double-check that the tank is securely fastened and that all the bolts, nuts, and washers are tight. Test the stability of the tank by gently trying to move it; it should not shift or wobble.
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Use gravity feed or a pump to transfer fuel
When installing an auxiliary fuel tank, you may want to consider using gravity or a pump to transfer the fuel. Gravity feeding is prohibited in some places, so be sure to check the local laws and regulations before opting for this method. If you're using gravity to feed fuel from one tank to another, you must have appropriate valves, such as shut-off, vent, and overflow valves. A manual shut-off valve will also be necessary to use a gravity-fed tank with a solenoid.
If you're looking for a more flexible option, using a pump to transfer fuel can be a great choice. This method allows you to fill your tank on the move without having to stop every few hundred miles to refill manually. There are different types of pumps available, such as the RDS kit, which includes a check valve that automatically keeps the tank full. However, keep in mind that this kit may not work with all truck models due to vent placement.
Another option is to use a 12-volt pump, which can be purchased separately. You can also use a pump with a normal hose and auto shut-off nozzle or tee off the filter down into the tank vent line. However, be cautious when using this method, as some users have reported issues with the gas cap not holding pressure, leading to leaks.
When deciding between gravity feed and a pump for your auxiliary fuel tank, consider the local regulations, your budget, and your preferred level of convenience. Remember to research the specific requirements and take the necessary precautions to ensure a safe and successful installation.
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Add a filter to either system for extra fuel purification
Adding a filter to your fuel system can provide extra fuel purification and help avoid a lot of potential issues. This is especially important if you are using diesel fuel, as water in diesel can cause significant damage to vital components.
There are two main types of fuel filters: primary and secondary. Primary fuel filters, also known as fuel filter water separators, separate water from fuel. This accumulated water can then be drained from the filter drain valve. They are typically mounted on the suction side of the fuel pump and have a nominal efficiency of 10-30 microns.
Secondary fuel filters, on the other hand, capture very fine levels of particulate contamination to prevent damage to highly sensitive components like pumps and injectors. They operate under much higher pressures than primary filters and have a nominal efficiency of 4-10 microns. For a modern engine with common-rail fuel injection, you will need a filter with a rating of 4 microns or smaller.
If you decide to use an inline fuel filter, you will need to prime the filter before installing it. You can purchase the necessary parts for your fuel filtration system from various retailers, including McMaster Carr, eBay, or Amazon. Ensure that you use a fuel hose that is approved for your purpose, and always double-clamp connections and seal threaded connections with an appropriate plumbing sealant.
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Frequently asked questions
The installation process will vary depending on your vehicle. Here are the general steps to follow:
- Ensure you have enough space to work safely and remove any items inside the bed of the truck.
- Place the auxiliary fuel tank in the desired location, ensuring it is not too close to the sides, front, or back of the bed.
- Mark the holes where you will install the tank, using a brightly coloured marking tool to avoid drilling mistakes.
- Drill the holes and use bolts, nuts, and washers to fasten the tank in place. Consider using an extra set of hands to hold the nuts and bolts in place.
- If your truck bed has rubber plugs, you can remove them, cut a hole in the centre, insert the rubber fuel line, and run it towards the factory fuel neck.
- Prime the fuel filter if you are using an inline filter.
- Depending on your preference, you can use a gravity feed or a pump-based system to transfer fuel from the auxiliary tank to the main tank.
Auxiliary fuel tanks provide extended driving capability and peace of mind during emergency situations, ensuring that you always have enough fuel for your journey.
Always ensure you have enough space to work safely and avoid drilling holes in the wrong places by marking them with a brightly coloured tool. If you need to lift your truck, use a jack with a high enough rating to do so safely.
