Mercedes Mullins
Installing an electric switch for a 2-fuel tank system can be done in several ways. One method involves using a dual tank switching valve selector, which allows you to run two separate fuel tanks and draw fuel from only one tank at a time. This valve is usually located between the fuel pump and the fuel tank, and it is important to note that it is not suitable for systems with in-tank fuel pumps or those with fuel return lines. Another approach is to utilize a transfer pump and a momentary switch to connect the two tanks separately. Additionally, some vehicles may employ two separate fuel lines, one from each tank, that converge at a 12v solenoid-operated fuel valve, enabling the selection of the desired fuel source.
Characteristics and Values of Installing an Electric Switch for a 2 Fuel Tanks System
| Characteristics | Values |
|---|---|
| Fuel Selector Valve Kit | FV1/FV1T |
| Number of Ports | 3 |
| Number of Inlets | 2 |
| Number of Outlets | 1 |
| Hose Barb Size | 5/16" |
| Voltage | 12V |
| Accessories | 3x stainless steel hose clamps, 12' 10GA wire, inline fuse and fuse holder, butt and eyelet connectors |
| Fuel Line Hose Size | 3/8" (10mm) |
| Fuel Line Hose Material | NBR Rubber |
| Fuel Line Hose Pressure Rating | 300 PSI |
| Fuel Pump Mounting Location | Directly in front of the selector valve |
| Fuel Line Hose Routing | Away from engine heat |
| Fuel Line Hose Type | Heavy-duty rubber fuel hose |
| Fuel Gauge | Single dashboard gauge |
| Fuel Level Equalization | Connect vent lines between the two tanks |
| Fuel Transfer Method | Transfer pump and momentary switch |
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What You'll Learn
Understanding the fuel tank system
Fuel Tank System Components:
The fuel tank system in a vehicle with two fuel tanks typically consists of multiple components working together. These include the fuel tanks themselves, fuel lines, a fuel valve, a fuel pump, and a fuel gauge.
Fuel Lines:
In a dual-tank setup, there are usually two separate fuel lines, one originating from each fuel tank. These fuel lines carry the fuel from the respective tanks towards the engine, where it is combusted to generate power.
Fuel Valve:
The fuel lines from the two tanks converge at a fuel valve, which acts as a control point. This valve is often a 12v solenoid-operated valve, allowing for precise control over the flow of fuel from each tank. The valve has two inlets, receiving fuel from the tanks, and one outlet, directing the fuel towards the engine.
Fuel Pump:
After the fuel valve, the fuel line continues to the fuel pump. The pump plays a crucial role in pressurizing and delivering the fuel to the engine at the required rate. The pump ensures that the engine receives a consistent and adequate supply of fuel for optimal performance.
Fuel Gauge:
To monitor the fuel level in each tank, vehicles often employ a fuel gauge. In some setups, there may be a shared fuel level gauge, requiring simultaneous switching of the fuel source and the fuel gauge. This ensures that the gauge accurately reflects the fuel level in the active tank.
Selector Valve Kits:
When installing an electric switch for a two-fuel tank system, you may need to use a selector valve kit. These kits, such as the FV1/FV1T Fuel Selector Valve Kit, are designed for vehicles with one main and one auxiliary fuel tank. They come with the necessary components, including hose clamps, wires, fuses, and connectors, to facilitate the installation process.
By understanding the fuel tank system's components and their functions, you can more effectively install and maintain an electric switch for a two-fuel tank setup, ensuring the vehicle's performance and your peace of mind.
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Choosing the right parts
Fuel Tanks:
The first step is to select the appropriate fuel tanks for your vehicle and requirements. Consider the capacity and placement of the tanks. Some vehicles have one tank on each side, while others may have a single larger tank installed in the rear. Ensure the tanks are compatible with your vehicle's fuel type, whether it be gasoline or diesel.
Fuel Pump:
You will need a fuel pump to draw fuel from the tanks and supply it to the engine. There are two main types to choose from: mechanical or electric. Electric fuel pumps offer advantages, such as starting to pump fuel when the ignition switch is turned on, preventing fuel evaporation in hot climates. They can also help with troubleshooting fuel flow problems as they produce a noticeable hum when functioning.
Fuel Selector Valve:
This is a crucial component that allows you to switch between the two fuel tanks. You can choose between a simple dual-port valve or a more advanced electric fuel tank selector valve. The number of ports depends on your setup, with options like 3-port or 6-port valves available. Ensure the valve is compatible with your fuel type and pressure requirements.
Fuel Lines and Hoses:
You will need fuel lines and hoses to connect the tanks, fuel pump, and engine. Consider using heavy-duty rubber fuel hoses instead of steel lines to reduce the possibility of vapor lock. Ensure the hoses are compatible with your fuel type and pressure ratings.
Fuel Gauge and Sender Unit:
A fuel gauge will indicate the fuel level in each tank. You can opt for a single dashboard fuel gauge that can be switched between the tanks or install separate gauges for each tank. Ensure the sender unit in the tank matches the gauge setup.
Clamps, Connectors, and Fuses:
Choose appropriate clamps and connectors for securing the fuel lines and hoses. Stainless steel hose clamps are commonly used. Additionally, consider inline fuses and fuse holders for electrical connections.
When selecting parts, always ensure they are compatible with your vehicle's specific make, model, and fuel system setup. Refer to manufacturer recommendations and consult with automotive experts or forums for guidance on choosing parts that are suitable for your particular application.
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Installing the switch
Installing an electric switch for a two-fuel-tank system can be done in a number of ways, depending on the vehicle and the setup of the fuel tanks. Here is a step-by-step guide on how to install an electric switch for a two-fuel-tank system:
Firstly, you will need to purchase a suitable dual-tank switching valve selector kit. These are available from automotive retailers and typically include the valve, hose clamps, wire, connectors, and a fuse. Ensure the product is compatible with your vehicle, especially if it has fuel return lines or is for marine use.
Next, locate the fuel lines from each tank. These will meet at a 12v solenoid-operated fuel valve, which should be mounted to the frame under the car, usually near the driver's seat. The fuel line then continues from the valve to the fuel pump.
Now, install the electric switch. This is typically a double pole, double throw electric toggle switch, which is mounted on the dashboard. This switch controls the solenoid valve and allows fuel to flow to the engine from the selected tank.
Connect the wiring from the switch to the solenoid valve, following the instructions provided with your kit. This wiring will energize the solenoid valve and allow it to function.
Finally, test the system. With the switch in position one, fuel should flow from tank one to the engine, and the fuel sending unit in tank one should connect to the fuel gauge. In position two, the system should draw fuel from the other tank and update the fuel gauge accordingly.
Some systems may also allow you to transfer fuel between the tanks, equalizing the fuel level in both. This can be done by adding a tube between the tanks at their lowest level, and using a momentary switch to activate a transfer pump.
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Wiring the system
Firstly, mount the fuel pump in front of the selector valve. Ensure you use a heavy-duty rubber fuel hose to route the new fuel line from the valve to the pump, avoiding any engine heat. This reduces the possibility of vapour lock. The electrical fuel pump can be wired to the ignition switch, allowing it to start when the ignition is turned on, rather than when the engine starts.
Secondly, install the solenoid valve. This valve has two inlets and one outlet, with the fuel lines from each tank meeting at this point. The valve is usually mounted under the car, near the driver's seat. The fuel line then continues from the valve to the fuel pump.
Thirdly, wire the dashboard switch. This is typically a double pole, double throw electric toggle switch. When the switch is in the first position, it energises the solenoid valve, allowing fuel to flow from tank one to the engine. Simultaneously, it connects the fuel sending unit in tank one to the fuel gauge. When the switch is in the second position, it performs the same functions for tank two.
Additionally, you may need to consider a fuel return line. Some systems require the fuel to return to the same tank, which can be achieved using a return-style fuel regulator. If you have a shared fuel level gauge, you will need to simultaneously switch the fuel source, return, and sender.
Finally, test the system. Ensure that the fuel gauge is functioning correctly and that fuel is flowing smoothly from the selected tank. You may need to make adjustments to ensure the system operates optimally.
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Testing the system
Once you have installed your electric switch for a two-fuel tank system, you will want to test it to ensure it works correctly and safely. Here is a step-by-step guide to testing the system:
Firstly, locate the switch and ensure it is in the correct position. Typically, there will be a dashboard switch with two positions, one for each tank. The switch should be clearly labelled, and you should be able to see or hear the pump running when the ignition is turned on. If it doesn't run, vibrate, or make a humming noise, there may be a fuel flow problem.
Next, test the fuel gauge. With the switch in position one, the gauge should display the fuel level in tank one. When you switch to position two, the gauge should adjust and show the fuel level in tank two. If the gauge does not adjust, there may be an issue with the fuel sending unit or the gauge itself.
Now, start the engine and let it run for a few minutes. With the engine running, switch between the two tanks. The engine should continue to run smoothly without any issues. If the engine stalls or loses power, there may be a problem with the system.
Additionally, pay attention to any unusual noises or vibrations coming from the engine. If you notice any unusual behaviour, switch back to the original tank and consult a mechanic or a professional for advice.
Finally, it is important to test the system while driving. While the vehicle is in motion, switch between the two tanks and observe the engine's performance. Ensure that the vehicle maintains power and drives smoothly. If there are any issues with performance or unusual noises, switch back to the original tank and seek professional advice.
By following these steps, you can safely test your new electric switch for a two-fuel tank system and ensure it functions correctly.
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Frequently asked questions
A dual fuel tank system allows you to run two separate fuel tanks and draw fuel from one tank at a time.
The installation process involves mounting a fuel pump to the frame in front of the selector valve. You will need to remove the mechanical fuel pump and cover the hole with a cover plate. Use a heavy-duty rubber fuel hose to route the new fuel line from the valve or electric fuel pump.
It is recommended to use an electric fuel pump that begins pumping when the ignition switch is turned on rather than when the engine starts. Turning on the ignition switch for a few seconds before starting the car can help fill the fuel bowl completely, which is beneficial in hot climates to prevent fuel evaporation.
You will need to ensure that the fuel gauge is functioning correctly and displaying the fuel level for the current tank. When refuelling, you will need to add fuel to both tanks to maintain equilibrium.
