Ameer Randolph
If you are having trouble switching over your Chevy truck's fuel tank, there are a few potential causes. The problem could be due to a faulty fuel pump or fuel filter, or a clogged filter. It could also be an issue with the diverter valve or the electric switch in the cab. To troubleshoot, start by checking the fuse, switch, and diverter to ensure they are all functional. You can test this by having someone near the electric valve hit the switch back and forth while you listen near the tanks to determine if the sending units are activating as they should. If this does not work, you may need to replace the factory fuel switch with a custom toggle or remove the dual-tank system entirely and install a fuel cell under the bed of the pickup.
| Characteristics | Values |
|---|---|
| Vehicle | Chevrolet C/K 1500 |
| Vehicle type | Pickup truck |
| Year | 1985 |
| Motor | 350 |
| Fuel tank type | Dual |
| Problem | Cannot switch to the left tank when the right tank is low on fuel |
| Possible causes | Failing fuel pump, clogged fuel filter, faulty diverter valve, faulty electric switch |
| Suggested solutions | Check fuse, test switch and diverter, replace electric toggle switch, convert from manual to electric switch, install a fuel cell under the bed of the pickup |
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What You'll Learn
Check the fuse, switch, and diverter valve
If you are experiencing issues with your Chevy truck's dual fuel tank switchover, one of the first things you should do is check the fuse, switch, and diverter valve. Here is a step-by-step guide to help you through the process:
Check the Fuse
The fuse is an essential component in the electrical system of your Chevy truck, and it is crucial to ensure it is functioning properly. Here are the steps to check the fuse:
- Locate the fuse box: The fuse box in Chevy trucks is typically located under the hood.
- Inspect the fuse: Check if the fuse for the fuel gauge or the fuel pump appears blown or damaged.
- Replace if necessary: If the fuse is blown or damaged, replace it with a new one of the same type and rating.
Check the Switch
The switch allows you to toggle between the two fuel tanks. To check its functionality:
- Observe the switch: Inspect the switch for any visible signs of damage or wear.
- Test the switch: Have someone near the electric valve hit the switch back and forth while you listen near the tanks. Ensure that the sending units are activating as they should.
- Consider replacement: If the switch is faulty, consider replacing it with a custom toggle that has similar wiring.
Check the Diverter Valve
The diverter valve plays a crucial role in directing fuel flow between the two tanks. Here's how you can check it:
- Identify the type of diverter valve: Determine whether you have a solenoid or manual diverter valve.
- Check the fuse: If you have a solenoid valve, check the corresponding fuse.
- Test the valve: Listen for any unusual sounds or restrictions that may indicate an issue with the diverter valve.
- Inspect for leaks: Leaks around the diverter valve can cause issues with the fuel tank switchover.
- Clean or replace: If the diverter valve is clogged or malfunctioning, consider cleaning or replacing it.
Remember, it is important to perform these checks safely and consult a professional mechanic if you have any doubts or concerns.
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Test the electrical diverter
To test the electrical diverter, start by checking the fuse. Then, ensure that the switch and the diverter are working. One way to test this is to have someone toggle the switch near the electric valve back and forth, and then do the same near the tanks. You should be able to hear if the sending units are functioning as they should.
If the switch is not the issue, the problem may lie with the diverter valve. This could be due to a restriction caused by the valve not slamming shut properly. If you have a solenoid, check the fuse, and if it is a manual diverter, it may need to be serviced.
Another potential issue could be with the fuel pumps or filters. One pump may be failing, or a filter may be clogged. Check the fuel fuse, filter, and ensure that the pump is plugged in.
If you still cannot identify the issue, it may be necessary to convert from a manual to an electrical setup, or to remove the dual-tank system entirely and install a fuel cell with a high-performance sending unit.
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Check the fuel pump and filter
To check the fuel pump and filter on a Chevy truck, you can start by inspecting the screen for debris. If you notice any debris, replace the filter. You can also blow through the outlet side of the filter into a white rag or towel to check for this.
If you're experiencing issues with accelerating, especially on the highway, or your car won't start, you may have a clogged fuel line, fuel filter, pump, or injector. To check the filter, remove it from the vehicle and drain any excess fuel. Then, use a short piece of rubber hose on the filter inlet and blow through it, feeling for resistance. If there's significant resistance, your filter is clogged and needs to be replaced.
You can also use a fuel pressure gauge to test the fuel pump. These are available at auto parts stores or can be borrowed from machine shops. Locate the fuel pump test point, usually near the fuel injectors, and hook up the pressure gauge. Consult your owner's manual for specific instructions as the location of the fuel pump varies between vehicles.
If you're dropping the fuel tank to access the pump, it's recommended to remove the fuel from the tank first. You may also need to remove the bed of the truck to access the pump, especially if you need to replace the lock ring, which can be rusted and difficult to remove.
If you're experiencing issues with the fuel pump, it's recommended to consult a professional mechanic or Chevy service centre to ensure the problem is correctly diagnosed and repaired.
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Test sending units
To test the sending unit of a fuel tank switchover on a Chevy truck, you can perform the following steps:
Firstly, consult your owner's manual to see if your Chevy truck has a built-in self-test procedure. Following the steps in the manual, you can initiate the self-test to check if the issue is with the gauge or the sending unit. If the fuel gauge does not complete a run from full to empty, the problem is likely with the gauge itself.
If the self-test is not available or inconclusive, you can proceed to inspect the top of the fuel sending unit for any damage, corrosion, or improper seating in the tank. Ensure that the connectors are clean to promote good conductivity, and verify that there is a proper ground connection.
To verify if the fuel sending unit is receiving the correct voltage, use a multimeter set to 20 volts. With the battery turned on, back-probe the input connector on the sending unit and refer to the service manual for the expected voltage. If the input voltage is lower than specified, inspect the wiring from the sending unit to the battery as it may be faulty.
You can also check the output voltage to determine if there is a discrepancy between the voltage sent from the fuel sending unit and the fuel gauge. If the voltage is different, there may be corrosion or poor wiring between the sending unit and the gas gauge.
If you suspect that the issue is with the sending unit itself, you may need to remove it from the fuel tank to manipulate the float arm while measuring resistance. Before removing the unit, ensure that the area is clean, dry, and free of corrosion to prevent debris from falling into the fuel tank. Refer to the vehicle's repair manual for the correct procedure to remove the unit.
With the sending unit outside of the tank, you can use a multimeter set to the Ohms setting to check the resistance performance. Consult the service manual to determine the expected resistance or Ohm values for the specific fuel tank sending unit under test.
Additionally, you can measure the resistance of the sender wire to ground to determine if the sending unit is functioning correctly, even with varying fuel levels in the tank.
It is important to note that fuel senders have a rheostat that provides resistance to ground. As the fuel arm moves from empty to full, the resistance seen by the fuel gauge changes. Therefore, proper grounding of the sending unit is essential for accurate fuel gauge readings.
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Convert from manual to electrical
If you are experiencing issues with switching between your dual fuel tanks in a Chevy truck, there are a few troubleshooting steps you can take. Firstly, check the fuse, switch, and diverter to ensure they are all functional. You can test the electrical diverter more easily than a manual one, as the latter requires you to pull it to check.
If the issue persists, it could be due to a faulty fuel filter or fuel pump. In this case, you might need to replace these components. Additionally, check for any clogged filters, as this could also be causing the problem.
If the above steps do not resolve the issue, you may need to convert from a manual to an electrical system. This involves customising the switch in your cab to something more robust than the factory fuel switch, which is known to be cheaply made. You can replace it with a custom toggle that has similar wiring.
If, after making these adjustments, the system still does not function correctly, you may need to remove it entirely and install a fuel cell under the bed of the pickup with a high-performance sending unit. Be cautious of cheaply built filter socks on the sending units and opt for higher-quality alternatives.
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Frequently asked questions
There could be a problem with the electric switch in the cab, the diverter valve, or the fuel pump or filter.
First, check the fuse, then make sure the switch and the diverter are both working. You can test the electrical diverter more easily than a manual one.
You can try replacing the factory fuel switch with a custom toggle that has similar wiring. If that doesn't work, you can remove the dual fuel tank system and install a fuel cell under the bed of the pickup with a high-performance sending unit.
Start from the switch, then move to the diverter, and then each sending unit.
Be aware of cheaply built filter socks on the sending units. Also, make sure to only use high-quality fuel to avoid silt build-up, which can lead to frequent pump replacements.
