Problems with Fuel Tank Replacement Every BMW E38 (1994–2001) Owner Should Know About — and Their Solutions

Why Original Fuel Tanks Are Nearly Impossible to Find, What Problems Arise from Aging Metal, and How Plasticautotank.com Offers a Real Solution for BMW E38 (730i, 735i, 740i, 750i) 1994–2001

The BMW E38 is a legendary 7 Series, valued today for its comfort, design, and timeless status. But with the model now 25–30 years old, maintenance becomes increasingly challenging. One of the most common and frustrating issues owners face is the need to replace the fuel tank — and that is where multiple problems begin.

1. Original BMW fuel tanks are no longer produced

The biggest issue is the severe shortage of new OEM metal tanks for BMW E38 models.

• production ended many years ago;
• no new units remain in official warehouses;
• most available options are used tanks in unknown or poor condition.

Owners spend weeks browsing forums, salvage yards, and classifieds — usually finding only rusty or damaged tanks priced unreasonably high.

2. Metal corrosion makes most used tanks unusable

All E38 models came with metal fuel tanks that deteriorate over time. Common issues include:

• rust on the bottom due to road salt and chemicals;
• corrosion around seams and mounting points;
• internal rust and flaking caused by old fuel deposits;
• micro-cracks from age, impacts, and vibration.

Even if a used tank looks acceptable externally, it may already be leaking or internally damaged. Many owners notice the problem only after smelling fuel inside the cabin or seeing wet spots under the car.

3. Tanks are not interchangeable across all E38 versions

A common misconception is that “any E38 tank will fit.” In reality, owners encounter major compatibility problems because tanks differ by:

• shape and capacity;
• ventilation and EVAP system layout;
• fuel level sensor configuration;
• engine type (gasoline vs diesel);
• pre-facelift vs facelift design.

As a result, many owners buy a tank from a salvage yard only to discover that it doesn’t fit or cannot be installed properly.

4. Repairing a metal fuel tank is expensive and unreliable

Restoring a metal tank may seem like a good alternative, but it usually creates new issues:

• sandblasting and welding can lead to new cracks;
• sealants do not guarantee long-term durability;
• internal rust continues to develop even after treatment;
• restoration cost often approaches the price of a new replacement.

And in the end, you still have an old metal tank with limited lifespan.

5. Driving with a damaged tank is a serious safety risk

A worn or leaking tank can cause:

• a persistent smell of gasoline inside the cabin or garage;
• unstable fuel pressure and engine performance issues;
• increased fuel consumption due to evaporation;
• a dangerous fire hazard.

Any fuel leak is a critical problem that requires immediate replacement.

6. BMW does not offer modern alternatives for the E38

Although modern cars use plastic tanks that are lighter, safer, and rust-proof, BMW never released a plastic fuel tank for the E38. This leaves owners choosing between:

• rare and deteriorating used metal tanks, or
• expensive and questionable restoration work.

7. Plasticautotank.com — manufacturer of plastic fuel tanks for BMW E38

To solve this long-standing issue, Plasticautotank.com manufactures new plastic fuel tanks fully compatible with BMW E38 (1994–2001).

Advantages of our tanks:

• plastic does not rust — no internal or external corrosion ever;
• significantly longer lifespan compared to metal;
• precise OEM-matching geometry for perfect fit;
• full compatibility with fuel lines, sensors, and mounting points;
• lightweight, durable, and resistant to chemicals and road salt;
• bolt-on installation with no modifications required.

A plastic fuel tank is a modern, reliable, and permanent solution to a problem that has bothered E38 owners for decades.

Conclusion

Finding a good original metal fuel tank for the BMW E38 has become nearly impossible. Corrosion, scarcity, poor compatibility, and high repair costs turn the replacement process into a serious challenge.

Plasticautotank.com provides the solution — a brand-new, durable, corrosion-resistant plastic tank designed specifically for BMW E38 (730i 735i 735i 740i 750i) 1994-2001.