Premium Plastic Fuel Tank for Mercedes-Benz G-Class (1975–2001) – Diesel Models

Replace Your Rusted Steel Tank with a Modern, Corrosion-Free Solution

This plastic fuel tank is a reliable and modern replacement for the original steel fuel tanks fitted to Mercedes-Benz G-Class diesel models (W460, W461, W462, W463, and Wolf GL variants manufactured between 1975 and 2001). If your original metal tank has started to rust, leak, or show signs of corrosion, this composite tank is the ideal solution for restoring your fuel system to reliable operation.

Why Choose a Plastic Fuel Tank?

Corrosion-Free Design: Unlike steel tanks that rust over time, our composite material is naturally resistant to rust and corrosion, ensuring decades of reliable service even in harsh conditions or salt-laden environments.
40–50% Lighter Than Steel: Reduces overall vehicle weight, improving fuel efficiency and taking stress off suspension and chassis components.
Impact-Resistant & Durable: Made from composite material (polyester resin, fiberglass, and carbon fiber), the tank combines strength with flexibility, resisting stone strikes and vibration damage.
Factory-Precise Fit: Manufactured to match original dimensions and mounting points exactly, ensuring drop-in compatibility with W460, W461, W462, and W463 frame configurations.
Internal Baffles Included: The tank features factory-pattern hydro-impact baffles that reduce fuel sloshing during off-road driving and aggressive maneuvers.
100% Pressure-Tested: Every tank undergoes rigorous pressure testing to guarantee zero fuel or vapor leaks.

Installation & Support

The tank mounts securely to the original factory mounting points and brackets. A detailed installation guide is included in the “Installation Guide” tab above, covering removal of the original tank, transfer of the fuel pump/sender unit, and proper reconnection of all fuel lines and electrical connectors.

Not sure if this tank fits your specific model? Contact us via WhatsApp at +371 20719490, or email plasticautotank@gmail.com with your vehicle’s model year, engine type, and VIN (Fahrgestellnummer) and we’ll confirm compatibility and answer any pre-purchase questions.

Quality & Warranty

Manufactured in Latvia under EU technical regulations and standards. Every tank is individually pressure-tested and comes with a 3-year manufacturer’s warranty covering material defects and manufacturing quality. Worldwide insured shipping is included.

Restore your Mercedes G-Class fuel system to reliable, rust-free operation today.

Questions about this tank? Write to us in the WhatsApp chat.

💡 Response time: 24/7 chatbot support for product and order inquiries. Responses are usually provided within 5 seconds.

Mercedes-Benz G-Class (Diesel, 1975–2001) Fuel Tank Replacement Checklist

Safety first: If you’re not comfortable working with fuel systems or heavy lifting, hire a professional.

Safety Checklist

Before starting work, prepare the following safety equipment:

Safety glasses
Gloves
Long-sleeved clothing
Fire extinguisher
Adequate ventilation
No smoking or open flames
Disconnect the vehicle’s battery

Tools & Materials

Floor jack
Jack stands
10–19 mm wrenches
Plastic scraper
Safety wire
Clean diesel fuel
Clear hose for priming
Socket set
Drain pan
Screwdrivers
Wheel chocks
Rags

Removal Steps

Relieve fuel system pressure before disconnecting any fuel lines.
Lift the vehicle and support it securely on jack stands. Place wheel chocks.
Disconnect the battery.
Drain the tank into a suitable container.
Disconnect electrical connectors and label hoses, lines, and wiring. Taking photos is recommended.
Disconnect the filler neck and vent hoses.
Support the tank using a floor jack with a piece of wood underneath.
Remove the tank straps and any protective shields.
Lower the tank slowly, making sure no hoses or wires remain attached.
Remove the sender/pump assembly, if installed on your model.

Install New Tank

Inspect the new tank and ensure that all fittings match your vehicle.
Transfer the sender/pump assembly if required, installing a new O-ring for proper sealing.
Position the new tank on the floor jack and raise it slowly into place.
Loosely install the tank straps, align the tank, then tighten the bolts to the correct torque.
Reconnect all hoses and lines (main line, return line, vent lines, filler neck).
Reconnect the electrical connectors.
Reconnect the battery.

Final Steps

Add a small amount of clean diesel to check for any leaks.
Prime the fuel system by turning the ignition on (without starting) or using a manual pump, depending on your vehicle.
Start the engine and carefully inspect for leaks.
Fill the tank fully and inspect again.
Perform a short test drive and recheck all connections and tank straps.

Troubleshooting

Engine won’t start or runs rough: Bleed the fuel system and verify all fittings.
Fuel smell: Inspect clamps, hoses, and the sender O-ring.
Leak at sender unit: Replace O-ring and reseat the assembly.
Corroded tank straps: Replace with new hardware.

Plastic fuel tank – Mercedes-Benz G-Class – Diesel (1975-2001)