OEM Subtank Retrofit/Install Project With Pics (1 Viewer)

[logicbyondreaso]

whats the cost to do one of these from a


parts perspective?

The price has gone up significantly since I last did this. Most parts are sourced from overseas such as Australia. In the 90's most Australians would convert their subtank for LPG use and these parts were available very cheap. Now it seems like they are reverting back to full petrol instead of dual fuel. Must be fuel price related to go through the trouble.
To add to the scarcity of parts, the cost of shipping is greater now as well. That said, expect to pay $2,500+

 

[logicbyondreaso]

Some progress.
I tested the entire system with all components out of the vehicle with no fuel in tanks. In order for this to work properly, the subtank needs to send a signal to the ECU that it has fuel. I removed the level sensor from the subtank and flipped it upside-down. This verified function of overhead gauge and provided the input for the ECU to transfer. Worked as designed. I then started to install each component.

Main tank outfitted with new filter, required sensor for subtank ECU, filler neck and new hoses.
Main tank was installed into place. Note: remove the driveshaft to give clearance for installation/removal.
Ran overhead console wiring harness through the A-pillar -> takes a little bit of patience. Then mounted the overhead console.
Subtank riv nuts and straps installed.
Transfer pump, filler neck, filler pipe mounted.
Subtank put in place

 

[logicbyondreaso]

More photos

Comparison of main tanks. Non-sub vs subtank versions. You will note the additional gauge bung on the right tank. This is needed for subtank ECU to work. I suppose it could be bypassed but then you risk overfilling the main tank.

Main tank float sensors for sub ECU. These prevent the system from transferring if level is high.

Another view of the transfer pump that is mounted underneath.

Added the OEM shift override button while the shifter was accessible. Not related to subtank.

 

[80Nomad]

Resurrecting an old thread, had the parts for a while now, didnt have time to do the install on my diesel 80s. Im missing the wiring harness with the triangular female plug 82169-60020 to connect the petrol 3 pin level sensor. Was anyone able to source the PN for it and the pins? I can make up my own harness. Thanks

 

[cruiserdan]

Resurrecting an old thread, had the parts for a while now, didnt have time to do the install on my diesel 80s. Im missing the wiring harness with the triangular female plug 82169-60020 to connect the petrol 3 pin level sensor. Was anyone able to source the PN for it and the pins? I can make up my own harness. Thanks

View attachment 3385039

Is the 5-digit number molded in that connector 11015?

 

[80Nomad]

Is the 5-digit number molded in that connector 11015?

It seems to be 11407

 

[cruiserdan]

It seems to be 11407

My old notes suggest it should be an 11015. However the 11407 uses the same repair splices as an 11015. I suspect that the mating housing is a 90980-11016. I know for a fact that the correct splice is an 82998-12440.

 

[cruiserdan]

Hang on.....
Change the connector body to 90980-11245 and use 82998-12440 splices.

 

[logicbyondreaso]

I made this document to help with clarification, repair, and making your own if you are short on wiring.

 

[80Nomad]

I made this document to help with clarification, repair, and making your own if you are short on wiring.

Thanks a bunch, what a great document. Based on your PN I also found another thread to confirm plugs are correct.

FSM Non-US Sub Tank diagram

I'd like to see the Non-US subtank FSM pages showing this set up. If you have these pages can you please post them. Also, I'd love to see a part number for the fuel transfer assembly for a 96 80 if someone has the EPC. I think I have read Kevin and George's write ups a 100 times, plus...

forum.ih8mud.com

 

[80Nomad]

My old notes suggest it should be an 11015. However the 11407 uses the same repair splices as an 11015. I suspect that the mating housing is a 90980-11016. I know for a fact that the correct splice is an 82998-12440.

Thanks, its seems that I need the female plug part #90980-11245 and 3 wires (part #82998-12440)