How To Install Fixed Fuel Tanks


Whether you're replacing an old, damaged fuel tank or adding an additional tank to your boat’s fuel system, safety is the most important thing to remember.

Before you install, determine the best placement for your tank, which should be where the vent and hose connections will form the shortest line. If you’re unsure of any of the detailed procedures after reading this, seek professional assistance.

If you're unsure of what type of tank size or style is best for your boat, check out our range of permanent and portable models here

What You Need:

  • Tape measure
  • Flat-blade screwdriver
  • Pliers or wrench


1. Secure New Fuel Tank into Position

  • We recommend using the Moeller Permanent Fuel Tank Hold Down Kit or Topside Fuel Tank Hold Down Kit depending on which type of tank it is. DO NOT use foam to secure tank in place. 

2. Attach Fuel Fill Hose (See Figure 1, Step 1)

  • Slide the clamps loosely onto the fuel fill hose and slip the hose over the fitting, tightening the clamps into place from the end of the hose.
  • Tighten the second clamp and leave a 1/8 gap to ensure they do not touch. Connect an earth-end-ground wire to one terminal’s bases and use a S/S split ring lock washer and screw fitting to secure.

3. Attach Vent Hose (See Figure 1, Step 2)

  • Slide a small hose clamp onto the vent (or breather) hose and leave loose then slide the end of the hose over the vent fitting and secure in place by tightening a clamp from the hose end.

4. Attach Fuel Withdraw Hose (See Figure 1, Step 3)

  • Attach a barb into your withdraw (or fuel pickup) (See Figure 2) and then slip a clamp onto the withdraw hose and leave loose. Check length then tighten with a clamp at the end of the hose.

5. Test for No Leak Install (See Figure 3)

  • A leak test should be conducted around seals and connections. Pressurize the tank to 3 PSI then use soapy water to look for air bubbles around these areas.

6. Proper Sender Wiring Installation (See Figure 4)

  • Connect sender wire from fuel gauge to the threaded screw terminal and use nut and washer to secure wire in place.
  • Connect a grounding wire to the fasson terminal on the fuel sender.

Products Mentioned In This Article:

Category: Installation

Related Articles