Plastic Fuel Tank for Mercedes-Benz G-Class Diesel 1975–2001

Replacement fuel tank for Mercedes-Benz G-Class diesel models, including W460, W461, W462 and Wolf.

This plastic replacement fuel tank is designed for Mercedes-Benz G-Class diesel models produced from 1975 to 2001. It is suitable for vehicles where the original steel fuel tank is rusted, leaking, damaged, or no longer reliable.

The tank is manufactured in-house in Latvia from a modern composite material based on polyester resins, fiberglass, and carbon fabrics. This material is resistant to diesel and gasoline and does not corrode like a traditional steel fuel tank.

Each fuel tank is pressure-tested after production to help ensure there are no fuel or vapour leaks before shipping.

Compatibility

Vehicle: Mercedes-Benz G-Class diesel
Chassis: W460, W461, W462 and Wolf
Production years: 1975–2001
Fuel type: Diesel
Fuel tank capacity: 70 L
Manufacturer numbers: A4604710098, A4614700004

Why choose this replacement fuel tank?

Corrosion-free alternative: composite plastic does not rust like the original steel tank.
Direct replacement: designed to fit factory mounting points and original fixings.
Internal baffles: hydro-impact baffles help reduce fuel movement inside the tank.
Pressure-tested: every tank is tested after production for fuel and vapour tightness.
Made in the EU: manufactured in Latvia in compliance with applicable European technical standards.
3-year guarantee: supplied with manufacturer warranty against material and production defects.

Installation

During installation, the fuel tank is secured to the original factory fixings. The tank is supplied as tank only, so fuel sender, pump, hoses, brackets, and other accessories are transferred from the original vehicle where required.

Need help checking compatibility?

If you are not sure whether this tank fits your Mercedes-Benz G-Class, send us your vehicle details or VIN in the WhatsApp chat before ordering.

💡 Response time: 24/7 chatbot support for product and order inquiries. Response within 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.