Defender Td5 - Fuel Pump Access Hole

**Mulgo** · 28th September 2006, 11:41 AM

Reading through some of the posted threads it seems that a few have problems with this fuel pump sitting in the tank.

After this problem out in the desert,

I decided to make an access hole for easy access to the fuel pump.

Attached are the details if you want to make one for yourself. Use 3mm aluminium to give it the necessary strength.

Any questions or if you want me to organise you a 'Kit' PM me.

Cheers,
Daniel

**ATH** · 28th September 2006, 11:51 AM

Thanks for that Vida.
I was going to post a question about this as the Disco is easy enough to access but Defenders are a pain in the butt. I presume that's measured from the rear door and then in to the edges of the hole you've cut? Did you just use self-tappers to hold the cover in place?
Alan H.

**Mulgo** · 28th September 2006, 12:08 PM

The 360mm are from the inside of the rear door and the 280mm are from the fold of the 'wheel arch'. Just make a small pilot hole for a start if you are a bit off you can always close it with a rivet. For me, these measurements were on the spot.

For the first access hole I did I used self-tappers, for the second one I made a proper lid.

Before you start working, just make sure you lower the tank a bit and put a metal or aluminum plate over the pump.

**Frenchie** · 28th September 2006, 01:07 PM

Hmm, you need to be careful with this. I suggested it when mine was done, but there is a body brace that runs over the top of the pump and if you cut that it can cause problems.

Kevin at Rovertech advised strongly against it as they had done something similar with another vehicle and ended up with bad body vibrations they couldn't get rid of.

**Mulgo** · 28th September 2006, 02:15 PM

It probably all depends how you do it. I never had any issues and therefore now installed it in my 130 station wagon as well.

The 3mm aluminium is strong enough to keep the strength dispite the missing 200mm of this brace.

I have already seen another 'fast-track' version. But it was not as strong. That guy just cut out a hole 250x250 and then fittet a aluminium plate over it.
The version I suggest has a smaller hole, just enough for the pump and has additional support.

**DEFENDERZOOK** · 28th September 2006, 07:43 PM

are the dimensions given the same for 110 and 130......?

**bluetongue** · 28th September 2006, 09:32 PM

You would think that after over 50 years of pure design brilliance those Landy engineers could have designed and pre-manufactured in-the-factory an access hole in defenders....

**Mulgo** · 6th November 2006, 09:44 AM

Originally Posted by DEFENDERZOOK

are the dimensions given the same for 110 and 130......?

The dimensions are not the same. The measurements I mentioned earlier are for a 110 only.

emc · 7th July 2009, 09:15 PM

Is there anyway of lowering the fuel pump before cutting the floor.
Anybody know the exact procedure for doing this?
Thanks

**Mulgo** · 7th July 2009, 10:32 PM

Originally Posted by emc

Is there anyway of lowering the fuel pump before cutting the floor.
Anybody know the exact procedure for doing this?
Thanks

1. Put a bottle jack under the steel plate holding the tank in place.
2. Undo the Land Rover 'tow' hooks and tow bar if one fitted.
2. Locate the two holes in the rear chassis member to the left and right of the spot where you could fit the tow hook. You should see a nut in each hole, unto them.
3. Undo the bolts at the front of the crossmember which hold the steel plate.
4. Lower the bottle jack about 5 to 10 cm (depending on the cutting device you will be using to cut the hole). You might need to undo the filler pipe to get the tank down far enough.

PM me or Skype in case you need further instructions.

Cheers,
Daniel

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