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PlasticAutoTank.com > Products > Plastic Fuel Tanks Mercedes-Benz

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

Exterior - Plastic fuel tank – Mercedes-Benz G-Class – Diesel (1975-2001)
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Top opening - Plastic fuel tank – Mercedes-Benz G-Class – Diesel (1975-2001)
Plastic fuel tank Mercedes-Benz G 1975 - 2000-scheme
PL0002

519.00€

Brand

Mercedes-Benz G-Class
Condition

New
Originality

Analogue
Guarantee

3 years
Made in

European Union

✔ In stock

Insurance-m Tank delivery is insured

Manufacturer number: A4604710098, A4614700004

Suitable for models: Mercedes-Benz G – W460, W461, W462, W463, Wolf gl – Diesel

Fuel tank capacity: 70 liters.

Material: Composite material based on polyester resins, glass fiber and carbon fiber fabric, resistant to diesel and gasoline and with a long service life.

Wall thickness: 5 mm

Weight: 8 kg

Size: 1280 x 630 x 340 mm

Equipment: tank only

The inside of the fuel tank has hydro-impact baffles made from factory drawings. The presence of partitions (serve to reduce fuel fluctuations).

During installation, the fuel tank is secured to the factory fixings.

The second hole is closed and can be cut out with a cutting wheel for a second additional tank.

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

Plastic fuel tanks are manufactured in-house – from a modern composite material based on polyester resins, fiberglass and carbon fabrics. They are highly reliable and nearly as resistant to impact as steel.

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

The fuel tanks are manufactured in Latvia in full compliance with the technical regulations and standards of the European Union.

Plastic fuel tank – Mercedes-Benz G-Class – Dizel

If you’re not sure which fuel tank is right for your car model, message us on contact us via WhatsApp and we’ll help you choose. 

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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

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

Install New Tank

  1. Inspect the new tank and ensure that all fittings match your vehicle.
  2. Transfer the sender/pump assembly if required, installing a new O-ring for proper sealing.
  3. Position the new tank on the floor jack and raise it slowly into place.
  4. Loosely install the tank straps, align the tank, then tighten the bolts to the correct torque.
  5. Reconnect all hoses and lines (main line, return line, vent lines, filler neck).
  6. Reconnect the electrical connectors.
  7. 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.