The fuel tank: function, purchase and replacement of the tank in the car

Cars with internal combustion engines need a sufficient supply of fuel to function reliably. This task is performed by the fuel tank. Sufficient quantities of petrol or diesel fuel can be filled and stored here. However, the fuel tank can break down or be damaged due to various causes. Find out now everything about the function of the fuel tank, how a defect becomes noticeable, how tanks are replaced and how you can get a replacement part at a reasonable price.

Fuel tank structure and function

The car’s fuel tank, together with other components, ensures a reliable supply of fuel to the engine. It holds a sufficient amount of petrol or diesel to be available to the vehicle’s fuel system while driving. Through appropriate connectors and fuel lines, the fuel tank is connected to the fuel pump and the filler neck behind the fuel filler cap.

The fuel tanks of modern vehicles often have a fuel pump integrated into the tank, or a built-in fuel unit. This component is a module that integrates the technology of the pump, a fuel gauge and sometimes a fuel filter. Older models, on the other hand, have a separate level sensor.

Where is the fuel tank located in the car?

Modern cars usually have a fuel tank in the rear body area. Here, the fuel tank is often located in the area of the rear axle. Sometimes the tank is hidden under the rear seat and is visible when the seat is removed.

Some models have a tank in the rear side panel of the body. However, especially in earlier times, the car’s tank was also located in other places. For example, classic cars may have a tank directly behind the dashboard or behind the seats.

What material are fuel tanks made of?

Nowadays, plastics are often used as the material for fuel tanks. In earlier times, however, the tanks were increasingly made of sheet steel or aluminium. Unlike steel tanks, modern plastic tanks cannot corrode.

This is a great advantage, as rust particles sucked in from steel tanks often became a problem in the past. In addition, materials such as plastic can be more easily moulded so that tanks can be optimally adapted to the shape of the car body in terms of design.

When the fuel tank is defective

A petrol or diesel tank can become defective for a variety of reasons. Since fuels can also leak out in this case, defective tanks should be replaced with a suitable spare part as soon as possible. You should no longer drive with a defective fuel tank and take appropriate countermeasures in the event of fuel leaks.

Defective fuel tanks should not be repaired under any circumstances, as the repair is rarely of long duration. It is better to replace defective tanks with original tanks. Used fuel tanks in good condition can often be bought at a reasonable price. Old and already rusted steel tanks in particular should be replaced before there is a problem.

These symptoms indicate that the tank is defective

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If fuel tanks on vehicles are damaged, petrol or diesel fuel will usually visibly leak from under the vehicle floor. Smaller leaks from tanks, on the other hand, are noticeable through symptoms such as a distinct petrol or diesel smell. If the fuel tank is rusted from the inside, rust particles can sometimes be found in the fuel filter. If fuel leaks from the tank in large quantities, the fire brigade in Germany must be notified by emergency call.

Signs of defective tanks on cars

• • Petrol or diesel leaks from under the car

• • Fuel odour is noticeable around the vehicle

• • Crack or other damage is clearly visible
  • Rust in the fuel system becomes a problem

How to replace defective fuel tanks

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If fuel tanks are damaged or severely corroded, replacement with a suitable replacement tank should take place as soon as possible. Since fuels such as motor petrol are, among other things, environmentally hazardous and highly flammable, only expert car mechanics should carry out the tank replacement.

After the old tank has been properly emptied, the component can be removed from the car. Depending on the vehicle manufacturer and model, various steps are necessary. All lines such as fuel lines, the filler pipe and the connections for the level sensor must be removed. Depending on the model, this is better done before or after loosening the tank mounting.

Fuel tanks are often fixed with tank straps under the vehicle floor. The tank strap acts as a kind of tension band, and is often made of metal. After the screw connections of the tank straps have been loosened, the fuel tank can be removed. The new fuel tank is fitted in the reverse order.

Three tips for changing the fuel tank

1. Fire hazard: When changing the fuel tank, residues of engine petrol or diesel fuel may escape. Make sure there is sufficient ventilation and fire protection.
2. Fuel delivery unit: If the previous fuel unit or petrol pump is still in good order, it can be transferred to the new fuel tank without further ado. Used tanks are sometimes offered including the unit.
3. Replace other parts: When changing the fuel tank, other already worn components can also be easily replaced. This concerns, for example, the level gauge, the inlet pipe, the tank cap or even an integrated fuel pump.

How to find the right tank for your vehicle

If the fuel tank is defective, a replacement of the component is inevitable. Autoparts24 carries an extensive range of fuel tanks that you can have delivered to your home free of charge. Steel tanks, aluminium tanks and plastic tanks as an OEM part are available here for a wide range of vehicle models.

You can easily find vehicle tanks for your car by entering the model name and vehicle manufacturer in the search mask. It is also practical to enter the manufacturer code number and type code number from the vehicle registration document. Matching fuel tanks and other used spare parts can then be easily compared.

Buy an original used fuel tank – these are the advantages

When you buy a used fuel tank, your purchase comes with numerous advantages. If you purchase used car parts from certified car recyclers, you will always get the original part that was already installed by the car’s manufacturer. However, the part is much cheaper in price than a new fuel tank. In addition, you protect the environment because used car parts do not have to be produced again.