Defender Td5 external fuel pump alternative





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  1. #1
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    Default Td5 external fuel pump alternative

    Hi All,

    Having owned two td5's, both of which have had failed fuel pumps, I am getting a little fed up with their reliability. I would like to place an external in-line fuel pump mounted on the chassis, I am thinking where the current fuel filter is. To do this my plans are to rip out the current pump, and remove the LP system. I will fit an aftermarket HP pre and post pump filter. The end system will be a direct line from the tank to the pump, which sends HP fuel to the fuel regulator, with a return line that goes directly back to the tank.

    I have read on this forum that some guys were thinking of doing it: https://forums.lr4x4.com/topic/71746...p-alternative/

    Thinking of using this pump https://www.injectorsonline.com/fuel...bosch-910.html which has the correct pressure at 5bar, however the flow rate is 130lph instead of the current LR pump of 180lph. According to the chaps on lr4x4, this isn't a problem.

    Reasons for doing this;

    1) Increased reliability
    2) Don't have to drop the tank in the middle of nowhere to replace
    3) Pump is cheaper, a lot cheaper
    4) Will be looking at doing a veg oil conversion in the future and the current Td5 pump WILL NOT be able to cope with veg oil. So this is future proofing that. But lets not focus on this for now haha.
    5) Bosch pumps can be found worldwide.

    So my questions are:

    1) Has anyone done this, or know of anyone that has done this?
    2) Can you recommend an external in-line pump that I can use that will supply the correct pressure and flow rate. Will the v8 pump work?
    3) Are there any major concerns with this system? With potential solutions?

    Thanks all.
    Land Rover
    Defender 110
    TD5
    @saffaoverland

  2. #2
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    Default Re: Td5 external fuel pump alternative

    One can buy the vdo pump only, and then fit into the existing housing. The pump costs in the region of R2500, so it's much easier and more cost effective to replace than do what you're planning to do.

    PM me for the VDO part number if you're interested.

    Edit: See here : https://www.4x4community.co.za/forum...mp-Part-Number
    Last edited by NewLandy; 2019/10/25 at 06:43 AM.

  3. #3
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    Default Re: Td5 external fuel pump alternative

    And on both the disco and defender td5 you dont have to drop the tank to get to the pump. Uou can access it from above.
    2000 Land Rover Discovery II TD5
    2016 Audi A3 1.8 TFSI SE S-Tronic 3Dr

  4. #4
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    Default Re: Td5 external fuel pump alternative

    Yep. I have previously done exactly what NewLandy says, and swopped over a new VDO pump onto the existing housing.

    at R2500.00 it really isnít worth re-inventing the wheel.

    i would also suggest cutting a hole in the floor pan and fitting a cover, so you can access the pump without dropping the tank out. The Doscoveries have this as standard, not sure why they didnít do it with Defender.

    my opinion regarding the flow rate, is that there is a pretty big difference in volume between 130lph and 180lph. That extra volume is going to make a big difference to the fuel temps, especially in High ambient temperatures, in low range.

  5. #5
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    Default Re: Td5 external fuel pump alternative

    Quote Originally Posted by FWM View Post
    And on both the disco and defender td5 you dont have to drop the tank to get to the pump. Uou can access it from above.
    In the defender you need to cut a whole in the floor pan to do this. It doesnít come with a hatch like the Discoveries do. But it is a very worthwhile mod to do.

  6. #6
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    Default Re: Td5 external fuel pump alternative

    Quote Originally Posted by RPiet View Post
    In the defender you need to cut a whole in the floor pan to do this. It doesnít come with a hatch like the Discoveries do. But it is a very worthwhile mod to do.
    Sorry then I was mistaken, my FIL's defender did have this mod then.
    2000 Land Rover Discovery II TD5
    2016 Audi A3 1.8 TFSI SE S-Tronic 3Dr

  7. #7
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    Default Re: Td5 external fuel pump alternative

    Other way you can do it is use a surge tank where you have one or two pumps which can be run sepretly so one is a spare and switched over with a switch
    you use a LP pump to pump fuel into surge tank and then that pumps HP to injectors through a filter as well and then back to main tank
    Attached Images Attached Images  
    1995 300TDi Defender with VGT Turbo
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift

  8. #8
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    Default Re: Td5 external fuel pump alternative

    Okay I'll cut a hole in the floor and make a hatch so I can access it easier.

    Any idea on where I can get a VDO pump from?

    https://www.spectromatic.net/product...y-2-5-td5.html

    I found this one from Bulgaria, works out to be R1250ish excluding customs.

    How easy is it to dismantle the fuel pump assembly to insert the VDO fuel pump?
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    Land Rover
    Defender 110
    TD5
    @saffaoverland

  9. #9
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    Default Re: Td5 external fuel pump alternative

    About a year ago i bought a BOSCH pump from Naskar spares in pretoria for R800. Most of these pumps seems to be the same dimentions. The one i bought was for VW or Audi and delivered 4 or 4.5 bar. I used it in my D2 td5 and its still working 100%
    Werner Smit

    2001 Defender 130 TD5
    2005 Discovery 3 TDV6
    2003 Discovery 2 TD5
    1999 Discovery 1 300tdi with lots of mods
    19 something Forward Control 2B

  10. #10
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    Default Re: Td5 external fuel pump alternative

    I dropped the tank the other day and it was a ###### job.

    https://youtu.be/qyat8WY2DRY

    Cleaned the tank and pump and put it together again.
    Today I finished the inspection hole. I dont want to drop that tank again.

    I would like the part number for the VDO or the Bosch pump please.
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    ONE LIFE!

  11. #11
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    Default Re: Td5 external fuel pump alternative

    Tsotsi on the forum here works for VDO in Jo-burg. I got a pump that I built back into the original plastic housing on my Disco 2 Td5. I had a thread running at the time with the correct part number that I will try to find and add here.
    This is the link to that thread with the part number.
    https://www.4x4community.co.za/forum...d.php?t=294115
    Last edited by Paul#25; 2019/10/25 at 08:48 PM.
    The humble person makes room for progress; the arrogant person believes theyíre already there.
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  12. #12
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    Default Re: Td5 external fuel pump alternative

    Quote Originally Posted by Wildkyker View Post
    I dropped the tank the other day and it was a ###### job.

    Cleaned the tank and pump and put it together again.
    Today I finished the inspection hole. I dont want to drop that tank again.

    I would like the part number for the VDO or the Bosch pump please.
    nicely done, neat job
    2012 Jeep Sahara Unlimited 3.6 V6
    Percivamus

  13. #13
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    Default Re: Td5 external fuel pump alternative

    Quote Originally Posted by Wildkyker View Post
    I dropped the tank the other day and it was a ###### job.

    https://youtu.be/qyat8WY2DRY

    Cleaned the tank and pump and put it together again.
    Today I finished the inspection hole. I dont want to drop that tank again.

    I would like the part number for the VDO or the Bosch pump please.
    do you have the measurements to the center on the cap or pump soone can do this
    thanks
    1995 300TDi Defender with VGT Turbo
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift

  14. #14
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    Default Re: Td5 external fuel pump alternative

    I searched the web and got this measurement for a 110.
    I first drilled a pilot hole to look through but it was off. After 3 more I got it centered.

    I will say the more correct measure is
    520mm from the very back of the door opening and 520.5mm from the right mudguard

    Dont let the drill sink too deep because the tank sits close to the crossmembers
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    Last edited by Wildkyker; 2019/10/26 at 11:00 AM.
    ONE LIFE!

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