300 conversion to fuel tank? - Defender Source
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  #1  
Old August 17th, 2010, 10:37 AM
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Paul D
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300 conversion to fuel tank?

So i am putting a 300 in my 90 and think that I neeed to remove the fuel pump from the old tank? Is that correct or do I just have to unplug the pump? seems like it should be removed but thought you guys could help.

Thanks
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Old August 17th, 2010, 11:15 AM
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Pull the tank & pull out the pump/fuel level assembly. I used one of those rubber straps to unscrew the top where the assembly is. Mark the lid and tank body, to make sure you re-tighten it about the same, before you take the "lid" off. Look over the fuel pump/level assembly and take out the pump portion and replace that section with a hose that can take submersion in diesel fuel. Also before you pull the tank mark the return hose and the IP feed hose where they enter the tank. Mix these 2 hoses up and you'll run out of fuel with the fuel guage showing 1/2 tank full. I did this myself, and besides driving me crazy, I had to pull the tank again, this time 1/2 full of fuel. Also the vent pipe goes to the engine compartment, on that end I places a cheapo gas filter to serve as an air filter for the breather. I also pulled out the vent valve internal components (springs & stops) in the top of the fuel tank to help in filling the tank. When filling, after the initial pop off of the gas pump, I'm able to get in 2 to 3 more gallons if I milk-it in. For me that equates to an extra 45 to 60 miles of extended travel range (I have a Zf auto box).
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Old August 17th, 2010, 01:33 PM
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Jim Cheney
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You need to replace the pump with a simple pick-up tube. There is a drop in part for the Tdi that will save you the trouble of modifying your existing one, and that might be good since a working D-90 fuel pump is worth a few dollars.
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Old August 17th, 2010, 08:34 PM
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Paul D
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thanks guys....

Also wondering what the tank outlet goes into......and where the return comes from...

I'm guessing the tanks outlet goes to the injection pump but not sure where and what about the return? I was going to have SS flexi lines made but I'm not sure how long they should be and where they go to and from. Thanks again for the help!!
Paul
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