|
Boy G
Expert
Date registered: Feb 2007
Location: Bushveld, South Africa
Vehicle(s): Diesel G's: 617A and 602
Posts: 1683
| 95 liter tank conversion questions
I have just fitted a 95 liter plastic tank into my current rebuild (460 pickup).
Can anyone advise me which wire goes where on the sender unit please? Ie old to new connections.
Also, will I have calibration issues between the new sender and the old guage?
Thanks. |
|
| |
|
AlanMcR
Expert
Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
| RE: 95 liter tank conversion questions
If you are lucky, the wire colors are still the same (see below)' If not, brown is ground. Then, the easy way to tell is to briefly touch the colored wires to the brown wire, one at a time (key on). One wire will light the reserve light, one will move the gauge. The yellowish one in the picture is the reserve light.
 (FuelSenderTop.jpg)
Attachments
----------------
 FuelSenderTop.jpg (79KB - 0 downloads)
|
|
| |
|
Boy G
Expert
Date registered: Feb 2007
Location: Bushveld, South Africa
Vehicle(s): Diesel G's: 617A and 602
Posts: 1683
| Re: 95 liter tank conversion questions
Thank you Alan.
Do you know what the smallest pipe in your picture is for? I have reconstructed that the big one is the breather, the medium one is the fuel supply, but the small one is a mystery. Fuel tank vent to atmosphere perhaps?? |
|
| |
|
bram_r
Expert
Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
| Re: 95 liter tank conversion questions
Boy G - 5/15/2017 9:19 PM
Thank you Alan.
Do you know what the smallest pipe in your picture is for? I have reconstructed that the big one is the breather, the medium one is the fuel supply, but the small one is a mystery. Fuel tank vent to atmosphere perhaps??
When checking the EPC on a 290GDT I found the diesel heater draws it's fuel throug it's own line all the way from the tank.
So not spliced from the diesel line going to the engine.
So I guess this tank connection is used when a diesel auxiliary heater is installed and you can run your hose from this hose connection.
gr. Bram |
|
| |
|
AlanMcR
Expert
Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
| Re: 95 liter tank conversion questions
Yes, the smallest line is for the stationary heater. That is an old picture where that line is topped with a rubber cap. I've since enlarged and repurposed this line to transfer between the extended range tank and the main tank. The pipes in the picture are: Bottom right: park heater Upper right: vent tube Upper left: feed to engine. I suggest using spring clamps like the vent tube has. Also, spray some preservative oil all over that cap. Water collects on it and it can rust badly. What you see in the picture is the results of 6 years on German roads.
Edited by AlanMcR 5/16/2017 1:02 PM
|
|
| |
|
Boy G
Expert
Date registered: Feb 2007
Location: Bushveld, South Africa
Vehicle(s): Diesel G's: 617A and 602
Posts: 1683
| Re: 95 liter tank conversion questions
Gotcha thanks.
I Will blank off the little one then. ( i still can not concieve of anyone needing a diesel powered additional heater in a car!)
I see my 460 filler neck has only one breather connector on it, but the larger tank requires two: LHS and middle = one connection and RHS = second connection. I think I will just tee the two rubber lines into one.
|
|
| |
|
AlanMcR
Expert
Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
| Re: 95 liter tank conversion questions
Boy G - 5/17/2017 12:42 PM Gotcha thanks. I Will blank off the little one then. ( i still can not concieve of anyone needing a diesel powered additional heater in a car!) I see my 460 filler neck has only one breather connector on it, but the larger tank requires two: LHS and middle = one connection and RHS = second connection. I think I will just tee the two rubber lines into one. There is supposed to be a distribution pipe that ties all the vents together.
|
|
| |
|
Boy G
Expert
Date registered: Feb 2007
Location: Bushveld, South Africa
Vehicle(s): Diesel G's: 617A and 602
Posts: 1683
| Re: 95 liter tank conversion questions
True, except there are two pipes that need connecting into the filler neck. The 460 filler neck (63 liter) only has one port, and the 461 filler neck (95 liter) has two. Not major.
|
|
| |
|
bram_r
Expert
Date registered: Apr 2007
Location: the Netherlands
Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD
Posts: 1659
| Re: 95 liter tank conversion questions
Boy G - 5/20/2017 10:09 PM
True, except there are two pipes that need connecting into the filler neck. The 460 filler neck (63 liter) only has one port, and the 461 filler neck (95 liter) has two. Not major.
You do have got the fuel tank install instructions right?
See attachment:
gr. bram
Attachments
----------------
tank conversion.pdf (739KB - 15 downloads)
|
|
| |
|
Boy G
Expert
Date registered: Feb 2007
Location: Bushveld, South Africa
Vehicle(s): Diesel G's: 617A and 602
Posts: 1683
| Re: 95 liter tank conversion questions
Thanks Bram!
No I had not seen that document yet but I have worked it out with a little help from my friends. It is in and most pipes connected. Just the wires left and the two breather pipes into one to match the 460 filler neck.
And then the big question. At 100km/hr will I get 1000km from a single tank of diesel. 617A, 5 speed, swb pickup, 4.89's?? I hope to finish the whole rebuild job by August and then we will see. |
|
| |
|
w.james
Veteran
Date registered: Jun 2006
Location: New Jersey
Vehicle(s): 84 280 GE 617A 5sp getrag
Posts: 239
| RE: 95 liter tank conversion questions
try thi
Attachments
----------------
tank conversion[1].pdf (739KB - 15 downloads)
|
|
| |
|
w.james
Veteran
Date registered: Jun 2006
Location: New Jersey
Vehicle(s): 84 280 GE 617A 5sp getrag
Posts: 239
| Re: 95 liter tank conversion questions
That the diesel, I have the gas but to big to post. PM with email and I will send |
|
| |
|
Boy G
Expert
Date registered: Feb 2007
Location: Bushveld, South Africa
Vehicle(s): Diesel G's: 617A and 602
Posts: 1683
| Re: 95 liter tank conversion questions
Tks WJ. Dont need the gas one.
Bram tagged the diesel one up there ^^ also.
Regards.
|
|
| |
|
bluegg
Veteran
Date registered: Nov 2016
Location: Oro-Medonte, Ontario, Canada
Vehicle(s): 1985 300GDT, 2003 Beetle 1.8t S, 1982 F350 SC Dual
Posts: 141
| Re: 95 liter tank conversion questions
bluegg here.
Where are you guys getting these plastic diesel tanks and senders?
Are we sure about the tubes out of the senders. I have gathered the large runs to engine as it goes right down through bottom cap inside filter .
Med is return line as it runs back beside the draw hole and the little nipple is vent for the sender itself.
I just removed tank from my 81 300GD donor.
By the rot it has to be original.
There was no wabasto in the truck but my hose configuration was as I stated above.
There was also a nipple in the top left side of tank which joined to the small nipple on sender with larger hose and reduction T Right side of reducing T went up to nipple on filler neck.
Sorry for all the words. I wish now I took a picture. |
|
| |
|
Boy G
Expert
Date registered: Feb 2007
Location: Bushveld, South Africa
Vehicle(s): Diesel G's: 617A and 602
Posts: 1683
| Re: 95 liter tank conversion questions
1. I got my tank complete with sender from a scrapped 461.
2. Read the document tagged in this thread. It explains a lot.
3. The tank breathers on the 460 steel tank of 63l is different to the 95 liter plastic tank. The 95l has three 12mm vents, LHS, RHS and middle one in sender unit.
4. In sender unit, medium size outlet is fuel supply and small one is webasto / extra heater.
5. Fuel return is 12mm tube front,left,middle of tank.
Edited by Boy G 6/11/2017 6:23 AM
|
|
| |
|
bluegg
Veteran
Date registered: Nov 2016
Location: Oro-Medonte, Ontario, Canada
Vehicle(s): 1985 300GDT, 2003 Beetle 1.8t S, 1982 F350 SC Dual
Posts: 141
| Re: 95 liter tank conversion questions
Boy G. Thanks for that info.
These G's have so many subtle differences through years and applications.
It can be daunting to try to put something together properly especially if you assume that what you took apart (working) until NOT is properly done in the first place.
There is limited literature on the 460's here in Canada and on the internet, it seems, because those only arrived here on the GREY import market and I believe many were shipped engines removed to save duty on complete vehicles the re-assembled without a lot of concern for detail.
I have an 85 280GE with a 617 turbo diesel and 4 speed manual. That's hardly original.
Original gas tank for M110 was left in an Gerry rigged to work.
I spend more time in research than wrenching and get many contradictory opinions.
The best stuff I find has the pics but lits in German. Me no sprekken ze deutch. |
|
| |
|
Boy G
Expert
Date registered: Feb 2007
Location: Bushveld, South Africa
Vehicle(s): Diesel G's: 617A and 602
Posts: 1683
| Re: 95 liter tank conversion questions
Just ask or search here. There is a ton of accumulated knowledge.
Your "hardly original" conversion is nonetheless and probably the most desirable conversion you can do on an old 460. It in fact increases its value and the structural changes to the vehicle are next to zero. (Mercedes themselves also built a few this way that we are aware of.)
The 95 liter tank conversion is what you will have to do if you buy a tank from MB for it. It supercedes the old tank, and in my case was a very easy job to fit.
I would argue that there has been very little change over the years 1980 to 2000. I have a few examples that fit into that range and there is very good part compatibility on them. |
|
| |
|
bluegg
Veteran
Date registered: Nov 2016
Location: Oro-Medonte, Ontario, Canada
Vehicle(s): 1985 300GDT, 2003 Beetle 1.8t S, 1982 F350 SC Dual
Posts: 141
| Re: 95 liter tank conversion questions
Thanks Andrew. So Mercedes Canada can supply a replacement tank for an 85 300GD?
I haven't asked them yet as some stuff they want incredible amounts of money for NOS. They even want to charge extra to remove the dust before I see it. Ha. |
|
| |
|
Boy G
Expert
Date registered: Feb 2007
Location: Bushveld, South Africa
Vehicle(s): Diesel G's: 617A and 602
Posts: 1683
| Re: 95 liter tank conversion questions
Yes MB in your neck of the woods would supply you with a new tank I believe. In exchange for large wodges of your cash.
There are a number of European used part merchants, like Offroad World, Cor Millenaar etc who would give you a better deal than new. Bram from Netherlands, on this site, not a trader afaik, but seems well G connected, might also be able to help you. |
|
| |
|
w.james
Veteran
Date registered: Jun 2006
Location: New Jersey
Vehicle(s): 84 280 GE 617A 5sp getrag
Posts: 239
| Re: 95 liter tank conversion questions
The tank in one price, and the kit to change the tank from 461 to 460 is expansive to. Got mine from Eurotruck about 10 years ago and I think it was a little more than 2k |
|
| |
