Fuel tank swapover - metal to plastic
Advice appreciated please.
Leaky metal tank on our '87 300GD SWB has gone far enough. Dropped the tank last weekend and the rot is worse than expected. Fully aware there are ways of sealing goosed metal tanks (Arrow Rads, Tank Re-nu, Northampton Autorads, etc. all come recommended), but I think it might be time to go plastic.
The showstopper will be just how much additional kit do we need to buy to make the switch? We're commited to buying new fuel hoses & sender unit whilst the whole lot is down anyway, but otherwise for cost reasons want to re-use as much of our metal tank ancillaries as possible (filler neck, brackets, breathers, etc.). If it makes any difference our tank sits fully on a metal tank guard which is held up by the two metal straps (I think I'm right in saying that some tanks sit directly on the straps themselves with no guard, but not ours).
I'd really appreciate any insight into the re-usability of parts as above, but also any tips on the build-up & installation itself. Thanks everyone and let me know if you need any more info....
Martin
Hi Martin,
it's all straight forward but you will have to replace the hose from the neck to the tank as they are different. The straps are the same but you will need a new bash plate if you want one (lots of folks don't have one) as they are a different size. Your insulation and guard from the exhaust cutout is probably not saveable so a new one of those too. Breathers are easy enough to make up from hose and nylon 'T' pieces.
After all that it will cost going on £150 to fill up as the capacity will be 90+liters
Hello Martin,
It would be of helpful if you could provide me with your chassis number; if your prefer, this; you can PM to me.
Although, I have not done this sort of modification; but as far as I know, when you buy a plastic tank, you have to buy a fitting kit which, I assume will have all you need. The upgrade is not cheap, guessing, you may be paying over £600 for the kit alone, the tank is of a similar price. With your chassis number, I don't mind looking into the matter for you and see what I learn.
Whilst, your tank is down, you may want to review the exhaust pipe condition that runs over the tank.
I think, you will find that having your tank repaired from one of the listed people, your self would be a cheaper option.
Please note my comments on prices is a rough rough estimate of what I think I know, so until I actually check this up, do not treat it as gospel.
Cheers,
Hello fastflap,
With the help of a forum member, Gav.helme; he has provided the information you wanted in detail.
I did approach my local dealer initially for this information and they gave me some sob story of having to contact M/Benz technical. Gav has gone to the trouble of looking up this information for you, over and above his normal duty, so it would be appreciated if you could PM and Thank him for his efforts as a favor to me.
The information he provides is as follows:
Metal tank is not available - Hence no price
Plastic one is available from Germany as follows (He means, it would have to be ordered from Germany, this may take upto ten working days to get to your local dealer).
A460 470 12 01 PLASTIC TANK £478.00 + VAT
A461 470 00 04 CONVERSION KIT £551.00 + VAT
Optional Tank Protection
A461 471 01 87 Tank Protection £142.00 + VAT
A461 470 02 85 Left Rear Guide Plate £22.40 + VAT
A461 470 04 85 Left Front Guide Plate £28.30 + VAT
A461 470 01 85 Right Rear Guide Plate £34.40 + VAT
A461 470 05 85 Right Front Guide Plate £28.30 + VAT
N009021 006103 Washer x6 £0.17ea + VAT
N000933 006074 Screw x6 £1.15ea + VAT
Optional for Vehicles with Right Additional Tank fitted (REPLACE TANK WITH EXTENDED NECK) - Your vehicle does not have this (long range tank fitting)
A460 470 13 20 Filler Neck NO LONGER AVAILABLE
Possibly replaced by A460 470 15 20 £133.00 + VAT
The conversion kit comes with everything you need to make the plastic tank fit including instructions I believe.
I am not 100% but i think the sender etc are all different from the steel tank.
So, based on what Gav has kindly provided above, your plastic conversion will cost over £1000. It would be cheaper to go the repairing route. Should you wish.
Cheers,
If you can find a plastic tank at a breakers or ebay.de there is no rocket science fitting one to a diesel after that. Petrol and diesel plastic tanks are the same (at least they are now/new, but did differ early on I think), you just ignore the mounting for the petrol pump. The sender units are different, you will need the diesel one, ideally already fitted to the tank you find (and it is plastic tank specific). Plumbing/breathing is logical on the diesels. One trick is joining a W460 filler neck to a plastic tank, the tank neck being narrower. The perfect fit here is the rubber neck from a W460 with auxiliary tanks. The W460 tank straps can be a very tight fit, but they usually do fit with some persuasion. Don't forget the rubber inserts for the straps, buy by the metre from MB or DIY it. You do not need a protection plate but if you want to fit one you need specific straps and brackets, not cheap. Another trick, turn the mudflap mounting bolts to face rearward so they do not stick into the tank. Source a good heatshield for where the exhaust passes over the tank, DIY again, I use old stock industrial boiler pipe lagging containing a certain banned material that begins with A. Alternatively take the opportunity to go for a side exit exhaust and eliminate that problem (you will need a W463 heat shield for the chassis leg ex breaker or ebay or again DIY). There are at least two sizes of plastic tank, 92L with the exhaust pass through, 96L if no exhaust pass through. EPC also lists a 100L tank but I now believe this is an error.
I have fitted five of these tanks, 3 to diesels, 2 to petrols. It is nice to know it is not going to rust, and the increase in range is useful (but painful at the pumps).
I believe it would also be possible to incorporate one W460 auxiliary tank (15L) at the filler neck but I never had one good enough to use.
The plastics were fitted to W460's from about 1988, to W461 possibly earlier, and to all W463. They all fit. The new 6x6 has a 150L tank which I presume will not fit.
I am open to correction on any of the above :-)
Eddie.
I am currently doing a twin tank on my 300GD and the filler neck of your old tank would be very useful ( HINT , HINT) as would the sender unit. Any chance of a discussion on condition and price of said units?!!!!!
Hello fastlap,
Just to let you know, the thread from rodnex has put up a posting for parts for sale,
amongst them is a PLASTIC TANK.
Cheers,
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Thank you so much everyone who helped ... ... ... very comprehensive advice and no stone unturned, which helps a lot and makes it sound like a job we could probably cope with.
Whether the price is something we could cope with is something for us to think about, now that we know abut the requirment for (and cost of!) the fitting kit. But all your info at least means we can go in with our eyes open and make a reasoned decision, so big thanks to everyone ...
Martin