fitting a td5 rear tank on a 200tdi chassis

I went on a jolly today, just under 3 hours each way to collect my new to me td5 rear tub as the tub on mine is a mess
I also have to buy a new tank as its like a tea bag so will be buying a new one
so has anyone done a fuel tank swop ie new style td5 on an old chassis 1992

hope this makes sense
its been a looooong day

I would find another way around it tbh , having a td5 tank makes doing a crossmember a pain in thee arse , also you would have to do something with the pump and sender, and its very vunerable sat at the rear, I have smacked mine twice today while offroad ( actual td5 defender )

yellow90 said:

I would find another way around it tbh , having a td5 tank makes doing a crossmember a pain in thee arse , also you would have to do something with the pump and sender, and its very vunerable sat at the rear, I have smacked mine twice today while offroad ( actual td5 defender )

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Bugger never thought of that
could you just extend the fuel line to reach the side tank ?

I think you'll get away without a pump, I don't think early 110s or discos had pumps at the back.

pump can be removed from sender unit and a stack pipe fitted to one pipe connector ,one used for return and other 2 blocked

greyhair said:

Bugger never thought of that
could you just extend the fuel line to reach the side tank ?

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do you mean the filler or the actual fuel feed and return lines? as the others have mentioned if its a TDI you wont need the actual pump running but you will need to have pipes in the tank and a sender unit ( I should have made that more clear)

my personal opinion would be to adjust the filler neck to reach the side tank as it wouldent be a difficult job, would be easier than fitting the td5 tank,keeps your original fuel pipe and sender standard,less likely to knock it offroad,means doing work to the back end is easier and also allows you to have a drain plug , I haven't checked but I wouldent think the plastic td5 tank has one

yellow90 said:

do you mean the filler or the actual fuel feed and return lines? as the others have mentioned if its a TDI you wont need the actual pump running but you will need to have pipes in the tank and a sender unit ( I should have made that more clear)

my personal opinion would be to adjust the filler neck to reach the side tank as it wouldent be a difficult job, would be easier than fitting the td5 tank,keeps your original fuel pipe and sender standard,less likely to knock it offroad,means doing work to the back end is easier and also allows you to have a drain plug , I haven't checked but I wouldent think the plastic td5 tank has one

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yes sorry that was my thought extend the rubber pipe from the filler neck to the original side tank

greyhair said:

yes sorry that was my thought extend the rubber pipe from the filler neck to the original side tank

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Yep I have seen it done like this. They had used standard silicone hose. But I've got no idea how well it would stand up to fuel.
I guess you can get fuel grade piping though.

greyhair said:

yes sorry that was my thought extend the rubber pipe from the filler neck to the original side tank

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that's personally how id do it

let us know what you decide and how you get on

Will do
but think im away off yet
just stripped the chassis
oh and the rear tub is still on the van roof in the drive
that was great fun driving back 3hrs with a defender tub strapped to the roof
oh well will teach me for not hiring a van
although to be fair I thought it would fit no problem in the back of a vivaro

bloody good job it was colled from the guys work place that had a forklift lol

will get a pic on later

greyhair said:

Will do
but think im away off yet
just stripped the chassis
oh and the rear tub is still on the van roof in the drive
that was great fun driving back 3hrs with a defender tub strapped to the roof
oh well will teach me for not hiring a van
although to be fair I thought it would fit no problem in the back of a vivaro

bloody good job it was colled from the guys work place that had a forklift lol

will get a pic on later

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haha was height a problem in the vivaro? last time I did something like this I collected two inside a high top transit how are you planning on getting it off your vans roof ???

yellow90 said:

haha was height a problem in the vivaro? last time I did something like this I collected two inside a high top transit how are you planning on getting it off your vans roof ???

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Sorted, parked it in next doors drive which is about 4/5 ft lower than mine then me and my old fella lifted it off

next job strip the old tub for capping etc for spares

ah that's not too bad , I once put a tonne of steel on the roof of a Passat estate, dident seem to go quite as well as it used to was slightly sluggish and a different shape...........

yellow90 said:

ah that's not too bad , I once put a tonne of steel on the roof of a Passat estate, dident seem to go quite as well as it used to was slightly sluggish and a different shape...........

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Thats what the kids called slammed these days
man im geting old

greyhair said:

Thats what the kids called slammed these days
man im geting old

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funny thing was after we removed the steel it never went back up ! it broke all springs so I just carried on on the bumpstops till something else happened to it lol

yellow90 said:

funny thing was after we removed the steel it never went back up ! it broke all springs so I just carried on on the bumpstops till something else happened to it lol

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bet that was a sight watching that drive down the road