Fitting a syncro fuel tank

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Fitting a syncro fuel tank

Postby pkrboo » 01 Jan 2020, 18:02

I have a 2wd DOKA and have acquired a petrol syncro fuel tank.(thanks daivoft1)When i convert to subaru power with RJES bellhousing i will fit this tank.

It is from a carb petrol syncro, so, as i will be fitting it to a fuel inecjtion engine i think there was an internal filter on the injection tanks? (if thats even still available?) will i need to fit it?

My plan curently is to fit an external filter with 11mm pipe in and out and then into the pump and then to engine. unless poeple say otherwise? whats your thoughts?
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Re: Fitting a syncro fuel tank

Postby 4x4 Bus » 01 Jan 2020, 18:48

Hi. Firstly you will need to drop the hight of your engine and box for tank to fit. If the tank is from an early 1.9 syncro then you will need the filter and kidney bowl ( swirl chamber). Filter screws into tank and holds kidney bowl in place.
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Re: Fitting a syncro fuel tank

Postby pkrboo » 01 Jan 2020, 19:10

hadn't thought about the difference in engine/box heights.

is the kidney bowl and filter available?
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Re: Fitting a syncro fuel tank

Postby 4x4 Bus » 01 Jan 2020, 19:28

Parts are no longer available.
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Re: Fitting a syncro fuel tank

Postby pkrboo » 01 Jan 2020, 19:37

ill stick with the external filter only then. just need to check height of the gearbox
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Re: Fitting a syncro fuel tank

Postby silverbullet » 02 Jan 2020, 14:50

The in-tank strainer is important, its what protects the pump from muck going through its bearings and pump vanes.

For reference, this is what the fuel return anti-surge "dish" and strainer look like.

Got to ask: why fit a syncro fuel tank to a 2wd?Image

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Re: Fitting a syncro fuel tank

Postby AIR_CHILLED » 02 Jan 2020, 15:06

Hello pkrboo,

I had the same problem when buying a Syncro fuel tank, I later discovered that I needed the swirl pot and strainer. The strainer has a part number but is NLA and the swirl pot does not have a part no. therefore must come as a job-lot when injection tanks were manufactured. I ended up sourcing them separately in the end.

As pointed out, it prevents the fuel pump being starved when going around corners etc...

I am also curious as to why your fitting the tank and are you going to fit the fuel filler panel too as per the donor Syncro/

Syncro conversion or duel fuel tanks?
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Re: Fitting a syncro fuel tank

Postby pkrboo » 02 Jan 2020, 16:38

I'm going to a Subaru engine and I would have needed to change tanks anyway as mine is an old, leaky probably rusty diesel tank.

So I acquired this tank cheap, its a bigger capacity. Means I am one step closer to a Syncro conversion if I go that route

I won't be going round corners fast but I may look at a swirl pot maybe. I will put a fuel filter pre pump.

I think mk1 golf's had a separate fuel pump and swirl pot type affair.

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Re: Fitting a syncro fuel tank

Postby pkrboo » 02 Jan 2020, 16:42

Plus i like the idea of higher ground clearance, if i fit a gearbox with a locking diff i will be "trying" to do some greenlaning 2d stylee

Yes I am fitting the Doka filler in the rear side panel.
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Re: Fitting a syncro fuel tank

Postby silverbullet » 02 Jan 2020, 17:18

In that case you'll need a packer between the trans nose mount and the rear crossmember* and 45mm packers for each end of the engine bar (to make them the same as wbx syncro)
Then give it a lift.

*no idea of how thick that needs to be

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Re: Fitting a syncro fuel tank

Postby pkrboo » 02 Jan 2020, 22:37

silverbullet wrote:The in-tank strainer is important, its what protects the pump from muck going through its bearings and pump vanes.

For reference, this is what the fuel return anti-surge "dish" and strainer look like.

Got to ask: why fit a syncro fuel tank to a 2wd?Image

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The kidney dish has me thinking about fitting a small aluminum tray inside the tank to act as the 'surge dish' istead of the plastic kidney dish

An MOD Mess tin may do the trick hole drilled on for the oulet and the return and 1 in each corner for fuel to flow in and out? or even a stainless steel camping bowl could work too i reckon?
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Re: Fitting a syncro fuel tank

Postby silverbullet » 03 Jan 2020, 08:27

The dish is held down by the filter, which has a male threaded spigot and screws into the tank. All tanks are threaded, its standard metric (coarse) about M14 iirc
The fuel return pipe on the level sender has a hose that simply goes through a hole drilled in the side of the dish.
It's pretty tight on space, hence the odd shape.

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Re: Fitting a syncro fuel tank

Postby pkrboo » 03 Jan 2020, 08:35

silverbullet wrote:The dish is held down by the filter, which has a male threaded spigot and screws into the tank. All tanks are threaded, its standard metric (coarse) about M14 iirc
The fuel return pipe on the level sender has a hose that simply goes through a hole drilled in the side of the dish.
It's pretty tight on space, hence the odd shape.

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thnaks for the info, i best take the sneder out and see what space tehre is for something "aftermarket"

did you ever make any filters, i think i read a thread where you were looking at recreating the coarse filter?
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Re: Fitting a syncro fuel tank

Postby AIR_CHILLED » 03 Jan 2020, 15:00

pkrboo wrote:I'm going to a Subaru engine and I would have needed to change tanks anyway as mine is an old, leaky probably rusty diesel tank.

So I acquired this tank cheap, its a bigger capacity. Means I am one step closer to a Syncro conversion if I go that route

I won't be going round corners fast but I may look at a swirl pot maybe. I will put a fuel filter pre pump.

I think mk1 golf's had a separate fuel pump and swirl pot type affair.

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Ok that sound like a really cool project. A Syncro conversion is as good as a bolt on upgrade for these vans should you later decide to go down that route, permanent and irreversible modification side :ok

A lifted Doka with Locking rear diff should be a very capable machine, the ground clearance when my lifted 2wd van was much better than in it's Syncro form.

For my next project I would love to find a 2wd Doka (Tristar or Jagdwagen would be nice!) and do a Syncro conversion on that but in stages to spread the cost.
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Re: Fitting a syncro fuel tank

Postby silverbullet » 03 Jan 2020, 19:45

Re: filter, I'll try and remember to measure this one before the tank is refitted and see what is possible.

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