Sylvie Willis
Installing an EFI-ready fuel system in a dual fuel tank setup requires careful planning and consideration. The process can vary depending on the vehicle and specific requirements, but there are some common steps and considerations to keep in mind. One key decision is whether to use a single or dual pump system, with the latter being more common to prevent cross-feeding between tanks and ensure adequate fuel supply. Additionally, the use of a surge tank or swirl pot can help balance fuel levels between the two tanks, but it may require additional pumps and modifications. The type of fuel pump and its location are also important, with in-tank pumps offering convenience, longevity, and quieter operation compared to external pumps. It's also crucial to consider the fuel return line setup, ensuring that fuel is returned to the appropriate tank and that the system can handle the pressure of electric pumps.
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What You'll Learn
Using a dual pump system
When installing an EFI system on a vehicle with dual fuel tanks, one of the main challenges is managing the fuel source and return lines. A dual pump system can be an effective solution for this setup. Here are the key considerations and steps for using a dual pump system:
Understanding the System: In a dual pump system, each fuel tank is equipped with its own electric fuel pump. These pumps can be low-pressure or high-pressure depending on the specific setup. The pumps draw fuel from their respective tanks and supply it to the engine, ensuring a consistent fuel supply during operation.
Selecting the Right Pumps: It is important to choose suitable pumps for your dual tank system. In-tank pumps, such as those offered by Holley, are popular choices as they are quiet, keep the fuel cooler, and can be more convenient and long-lasting compared to external pumps. Additionally, consider the pressure requirements and ensure the pumps can handle the necessary fuel flow rates.
Installing the Pumps: The installation process for the pumps will depend on the specific vehicle and pump kit being used. It is recommended to follow the manufacturer's instructions for the pump kit you have selected. Some general considerations include ensuring proper measurements and fittings, using pipe sealant on pump fittings, and marking the supply and return hoses to avoid confusion during connections.
Managing Fuel Return: One of the critical aspects of a dual pump system is managing the fuel return lines. It is essential to ensure that the fuel is returned to the correct tank. This can be achieved by using a motorized valve that switches both the fuel feed and the return lines simultaneously. This setup allows for precise control of the fuel flow and ensures that the fuel returns to the appropriate tank.
Using a Fuel Selector Valve: A fuel selector valve is a crucial component in a dual pump system. It allows you to switch between the two tanks seamlessly. A 6-port electric fuel selector valve is ideal for EFI-equipped vehicles as it can switch both the supply and return lines at the same time. This valve can be wired to the fuel gauge selector switch on your dashboard, enabling you to switch fuel tanks and monitor fuel levels simultaneously.
By following these considerations and steps, you can effectively install and utilize a dual pump system for your EFI and dual fuel tank setup, ensuring a reliable and efficient fuel delivery system for your vehicle.
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Electric fuel tank selector valves
The 6-port electric fuel tank selector valve is designed to switch both the supply and return lines simultaneously, making it a convenient choice for dual fuel tank systems. This valve can be easily wired to the existing fuel gauge selector switch on the dashboard, allowing users to switch between tanks for fuel delivery while also monitoring fuel levels in each tank. This setup ensures a seamless transition between the main and auxiliary tanks.
When considering electric fuel tank selector valves, it is important to assess the pressure requirements. Motorized valves, for instance, are designed for applications with in-tank fuel pumps and must operate within the rated pressure of the valve. Additionally, some vehicles may have specific requirements, such as the Chevy 4x4, which utilizes a toggle switch to operate a solenoid that switches the fuel pickup between the two tanks.
In terms of installation, electric fuel tank selector valves typically require mounting holes with threaded nuts for secure installation. The valves should be wired to the fuel gauge selector switch, allowing for seamless switching between tanks. It is also important to consider the hose sizes for fuel supply and return lines to ensure compatibility with the selector valve.
Overall, electric fuel tank selector valves offer a straightforward solution for dual fuel tank setups, particularly those equipped with EFI systems. By opting for these valves, vehicle owners can benefit from easy operation, efficient fuel management, and the ability to monitor fuel levels in each tank, making them a valuable component for dual fuel tank configurations.
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Plumbing and wiring
Plumbing:
Firstly, it is important to decide on the type of pump setup. Most dual tank setups use an electric pump in each tank with a check valve to prevent cross-feeding. These in-tank pumps are usually low-pressure delivery pumps that feed into a high-pressure frame-mounted pump. Alternatively, you can use high-pressure pumps in each tank and forego the frame pump. This simplifies the system and only requires a single toggle switch to control the power to each tank.
Another option is to use a surge tank (or catch tank) with two pumps behind the main tanks. This setup can help maintain fuel balance between the tanks, especially with the use of five-bar pumps, but ensure they do not run dry. Additionally, a crossover line with a single pump and fuel senders in each tank can be implemented for a clean and simple solution.
For the fuel lines, the EFI system will require both supply and return lines. The supply line brings fuel from the tank to the engine, while the return line sends the unused fuel back to the tank. The return line can be split to return fuel to each tank to prevent overfilling.
Wiring:
The wiring aspect primarily involves the fuel pump and the fuel gauge. The electric fuel pump requires wiring to power it, and this can be done through the ignition switch or a separate toggle switch. Ensure that common relays are used to power the pumps, as running multiple pumps through the ignition switch may not be feasible.
For the fuel gauge, you can wire it to the existing fuel gauge selector switch on your dash. This allows you to switch between tanks for fuel delivery while simultaneously monitoring the fuel level in each tank.
Overall, the plumbing and wiring process for installing an EFI on a dual fuel tank requires careful planning and consideration of the specific setup and components used. It is important to refer to detailed diagrams and instructions specific to your vehicle for a successful installation.
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Using a surge tank
A surge tank is a great option for your EFI setup. It can be used to maintain a reserve of fuel in front of the high-pressure pump, ensuring a constant supply to the engine. This setup is especially useful if you have a dual fuel tank setup, as it can help to balance the fuel levels between the two tanks.
The surge tank is typically taller than it is wide, with a fuel pickup at the bottom to feed your EFI system. The fuel pressure regulator returns fuel to the lower port on the side of the tank. The fuel level in the surge tank is maintained by pumping fuel from the main tank into the top fitting. Once the surge tank is filled, the excess fuel overflows from the upper side fitting back into the main fuel tank. This means that the feed from the main fuel tank does not need to be high pressure and can even use the stock fuel pump.
There are a few things to consider when setting up a surge tank. Firstly, you will need to decide whether you want an external tank or one that can be dropped into your existing fuel tank. If you choose an external tank, you will need to consider the location and layout, as well as the type of low-pressure pump to use. Additionally, you may need to modify your existing fuel tank to accommodate the return line from the surge tank.
Some people choose to use a stainless steel power steering reservoir tank as their surge tank, with a Holley blue pump to transfer fuel from the main tanks to the surge tank. From there, an Aeromotive A1000 pump draws fuel from the surge tank and sends it to the fuel rails, before returning to the surge tank. This setup has been known to work well for many people.
Overall, a surge tank can be a great option for your EFI and dual fuel tank setup, providing a constant supply of fuel to your engine and helping to balance fuel levels between tanks. With some careful planning and consideration, you can set up a surge tank that works efficiently for your vehicle.
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Installing a return-style fuel pump
Step 1: Understand the System Requirements
Before beginning the installation, it's crucial to understand the specific requirements of your vehicle's fuel system. This includes factors such as the type of fuel injection system, the location of the tanks, and the routing of fuel lines.
Step 2: Choose the Right Fuel Pump Kit
Select a fuel pump kit specifically designed for dual-tank vehicles, such as the EFI Fuel Pump Kit. Ensure it includes all the necessary components, like a motorized valve that switches the fuel feed, return, and fuel level.
Step 3: Consider the Fuel Pump Type
You can opt for low-pressure delivery pumps or high-pressure pumps. Low-pressure pumps are commonly used in Ford vehicles and feed into a high-pressure frame-mounted pump. Alternatively, you can use high-pressure pumps directly in each tank, eliminating the need for a frame pump.
Step 4: Install the Fuel Pump(s)
Install the fuel pump(s) in your vehicle, ensuring they are securely mounted and connected to the fuel lines. The exact installation process may vary depending on the pump type and vehicle specifications.
Step 5: Configure the Fuel Lines
Set up the fuel lines to ensure proper fuel flow. For a return-style fuel system, you will need to install a return line that directs excess fuel back to the tank. This helps regulate fuel pressure, keeps the fuel cool, and reduces stress on the pump.
Step 6: Install a Fuel Selector Valve
A fuel selector valve allows you to switch between the two tanks seamlessly. You can choose between a 3-port or 6-port electric fuel tank selector valve, depending on your specific setup. This valve should be wired to the existing fuel gauge selector switch, enabling you to switch fuel tanks effortlessly.
Step 7: Test and Verify
Once the installation is complete, thoroughly test the system to ensure proper functionality. Check for any leaks, verify fuel flow, and ensure that the fuel gauge accurately reflects the levels in both tanks.
By following these steps and consulting vehicle-specific resources and forums, you can successfully install a return-style fuel pump in your dual-tank setup, optimizing performance and fuel delivery.
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Frequently asked questions
There are a few options for incorporating electric fuel pumps in a dual fuel tank setup. One option is to put an in-tank pump in each tank and use a toggle switch to switch power between the two tanks. Another option is to use high-pressure pumps in each tank and skip the frame pump. A third option is to use low-pressure pumps in each main tank and have a high-pressure pump in a smaller third auxiliary tank.
It is recommended to spray some penetrating oil on the tank strap fasteners and scrub the threads with a wire brush. Fuel tank removal and installation is typically a two-person job, especially if there is fuel in the tank. After the tank is lowered, remove the original fuel hoses, sending unit wire, and ground wire.
One consideration for a dual fuel tank setup with EFI is the routing of the return EFI lines. Some options include having a return line to each tank or modifying the setup to return fuel to the main tank and using the auxiliary tank to fill the main. Another consideration is the use of a surge tank or catch tank to balance the fuel levels between the two tanks.
