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Thread: Tdi 90 with extra TD5 tank

  1. #1
    Join Date
    Jan 2010
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    Melbourne
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    1,240

    Tdi 90 with extra TD5 tank

    Ok so I have a TDI with the usual side tank under the drivers seat. I also have a TD5 tank with pump/sender sitting on the shelf in my garage.

    I can mount it between the chassis rails and figured out the pipework and how to make a dual filler. I am now wondering about the TD5 in-tank pump.

    I planned on using an external 12v transfer pump to take fuel from the TD5 tank and route it down an inlet on the original tank filler neck. But now Im thinking it would be nice to use the original in-tank pump for this, seeing as it is already there.

    I read here -> Replacing Td5 fuel pump with Bosch 044 inline pump
    - that its a two stage pump with 30 l/h lift and 180 l/h high pressure.

    So it has low send/return and high send/return. Could you run the low through a pre-filter and back and send the high as a transfer to the main tank and blank off the left over return?

    I'm guessing on the TD5 the faster side of the pump builds pressure behind the injectors. If this side of the pump was unrestricted it could move 180 l/h into the main tank right? But this is alot faster than the lift pump can supply so what happens there?

    And here's another one -> Does the pump work with the sender to cut out when fuel tank is empty?

  2. #2
    Join Date
    Aug 2006
    Location
    Melbourn(ish)
    Posts
    24,472
    take out the TD5 pump/sender unit and install the same from a TDI with an external pump fitted OR from a v8 disco and use the intank pump to handle the transfer (just dont let it run dry.)
    Dave

    "In a Landrover the other vehicle is your crumple zone."

    For spelling call Rogets, for mechanicing call me.

    Fozzy, 2.25D SIII Ex DCA Ute
    TDI D1(its responded well to its lecture about poor performance)

    If you've benefited from one or more of my posts please remember, your taxes paid for my skill sets, I'm just trying to make sure you get your monies worth.
    If you think you're in front on the deal, pay it forwards.

  3. #3
    Join Date
    Jan 2010
    Location
    Melbourne
    Posts
    1,240
    Right so you rekon these are the ones:
    v8 disco = PRC9409
    tdi sender = PRC8463

    both of these will fit in place of the td5 intank pump and give correct fuel level reading?

    Why cant the TD5 pump be used to transfer?

  4. #4
    Join Date
    Aug 2006
    Location
    Melbourn(ish)
    Posts
    24,472
    because its a single unit with 4 ports

    low out
    low in (this handles the filtration loop)
    high out
    return

    if you dont follow the normal routing of the lines you'll either kill the pump from not having any fuel flowing through the High pressure section or if you blank off the low pressure side you run the risk of damaging it on the low pressure side.

    Id suggest that if its a known working pump you can probably sell it onto a td5 owner as they are a fairly exxy part.

    as for the guage working or not thats going to depend on how you wire it up and if the guage has the same range as the sender. If you're fitting a second gauge one of the VDO units has the same range as the stock LR item and should be a straight up job to wire in but you might need to massage the float arm to get the sender to range correctly.

    you could loop the LP out to the LP in and then tap off the HP out from the TD5 pump but a, thats extra connections that can leak and if you're running off of the HP line and you get a leak its unlikely to be insignificant when it happens.
    Dave

    "In a Landrover the other vehicle is your crumple zone."

    For spelling call Rogets, for mechanicing call me.

    Fozzy, 2.25D SIII Ex DCA Ute
    TDI D1(its responded well to its lecture about poor performance)

    If you've benefited from one or more of my posts please remember, your taxes paid for my skill sets, I'm just trying to make sure you get your monies worth.
    If you think you're in front on the deal, pay it forwards.

  5. #5
    Join Date
    Jan 1970
    Location
    Brisbane
    Posts
    4,680
    In my 90 I have the tank under the seat and have a second tank put in the back. Not a td5 tank a designed long range tank for the 90. And to fit in the place of where the TD5 tank goes. So pretty much same thing.

    On mine I have a v8 fuel pump to pump the fuel from the rear tank into the under seat tank. This is controlled by a switch on the dash. When the front tank is getting empty I flick the switch and watch the rear tank fill up the front tank. Then carry on using the front tank fuel

    As for filling the rear tank. I have a y section on the original filler ( just behind the door) this means I can fill both tanks at the same time or with a twist of the filler fill the rear only or the front only. The rear filler pipe goes over the rear coil spring and over the chassis into the rear tank

    Ali
    95 300 Tdi Defender 90
    99 300 Tdi Defender 110
    92 Discovery 200tdi
    50 Series 1 80
    50 Series 1 80


    www.reads4x4.com

  6. #6
    Join Date
    Jan 2010
    Location
    Melbourne
    Posts
    1,240
    Blknight.aus
    True the TD5 pump hooked up (if possible) would be more complicated. If I can get a good V8 pump for cheaper than I can sell the TD5 one then it sounds like the way to go. Thanks!

    That said the low pressure send and return running through a pre-filter would add something to the set up and if connected up properly its no more likely to leak then on a factory TD5. So although it may not be as simple as using the V8 pump, it is a viable option unless the TD5 HP side sending an unrestricted flow will crap out the LP side (cant keep up)?

    If the TD5 HP will send 180 l/h what kind of rate does the V8 unit pump?

    Reads 90
    Your set up is pretty much what I am going for. Pete in Bournemouth told me about the dual tank set up on your 90 when I asked him about setting one up on mine last year! He done a chassis swap for me with
    a new ROW spec chassis that has TDI front and TD5 rear so I gained a mount for the rear tank.

    Unfortunatly time and money didnt allow me to get the tank hooked up before I shipped the rover over to Melbourne so I just bolted the TD5 tank on for shipping and now looking to hook it up myself.

    Did you make your dual filler or know a place I can buy one?

  7. #7
    Join Date
    Aug 2006
    Location
    Melbourn(ish)
    Posts
    24,472
    no, if you follow the same setup as the td5 runs in terms of fuel lines you wont risk the pump, Id put a slight restriction in the HP side just to give it some resistance to flow to prevent overspeed damage of the pump. (the LP side runs almost free from resistance unless the filter is clagged)


    My concern with the complication of plumbing it up is not that its overly complicated with too many joints in it its that some of the joints will be hand made joints and that introduces the potential for a problem. What it would cost you in terms of correctly rated parts to do what you want with the TD5 pump setup is likely to be more than it would cost you to go an grab the sender/pump assembly from a wreckers for a disco 1.

    From memory at open flow the v8 pump (early) shifts about 2-2.5l/min and the later ones do 3-4l/min.
    Dave

    "In a Landrover the other vehicle is your crumple zone."

    For spelling call Rogets, for mechanicing call me.

    Fozzy, 2.25D SIII Ex DCA Ute
    TDI D1(its responded well to its lecture about poor performance)

    If you've benefited from one or more of my posts please remember, your taxes paid for my skill sets, I'm just trying to make sure you get your monies worth.
    If you think you're in front on the deal, pay it forwards.

  8. #8
    Join Date
    Jan 1970
    Location
    Brisbane
    Posts
    4,680
    Quote Originally Posted by manic View Post
    Blknight.aus
    True the TD5 pump hooked up (if possible) would be more complicated. If I can get a good V8 pump for cheaper than I can sell the TD5 one then it sounds like the way to go. Thanks!

    That said the low pressure send and return running through a pre-filter would add something to the set up and if connected up properly its no more likely to leak then on a factory TD5. So although it may not be as simple as using the V8 pump, it is a viable option unless the TD5 HP side sending an unrestricted flow will crap out the LP side (cant keep up)?

    If the TD5 HP will send 180 l/h what kind of rate does the V8 unit pump?

    Reads 90
    Your set up is pretty much what I am going for. Pete in Bournemouth told me about the dual tank set up on your 90 when I asked him about setting one up on mine last year! He done a chassis swap for me with
    a new ROW spec chassis that has TDI front and TD5 rear so I gained a mount for the rear tank.

    Unfortunatly time and money didnt allow me to get the tank hooked up before I shipped the rover over to Melbourne so I just bolted the TD5 tank on for shipping and now looking to hook it up myself.

    Did you make your dual filler or know a place I can buy one?
    Ahh you know Pete From Stunning services ( or however you spell it )
    Well you will already know he fitted it. He used to do most of the work on my winch challenge trucks, roll cages and stuff. Nice chap and good at racing.
    My brother (Julian) and us used to all race together

    May be worth contacting the guys where I got my tank from as that is where it came from but would problely just as cheap to get one made here.
    I will hunt out the company but think they are called Safari 4x4 or something
    Ok here is the address of the company that built my kit http://www.safari-equip.co.uk/index.php?page=4

    Here is some pics of mine
    Attached Images Attached Images
    95 300 Tdi Defender 90
    99 300 Tdi Defender 110
    92 Discovery 200tdi
    50 Series 1 80
    50 Series 1 80


    www.reads4x4.com

  9. #9
    Join Date
    Jan 2010
    Location
    Melbourne
    Posts
    1,240
    thanks for the info guys.

    Im on the look out for a V8 disco pump, TD5 filler neck (to have welded to original) and the V8 pump wiring harness.

    I would have attempted the TD5 pump but I dont think I can get the connector plug. Getting a whole TD5 chassis loom or chopping one up just for the plug is not on. The V8 pump has a wiring harness you can buy seperately -> YMT100050.

  10. #10
    Join Date
    Jan 2010
    Location
    Melbourne
    Posts
    1,240
    any idea what year the later/faster V8 fuel pumps started?

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