HGV fuel tank replacement: when to replace and what to specify
Most modern HGV fuel tanks are made from either aluminium alloy or high-density polyethylene. Aluminium tanks are standard on European HGVs and are robust but susceptible to corrosion from road salts over time. Plastic tanks are lighter and corrosion-resistant but can crack from physical impact. Both types are a replacement item rather than a repair item in most cases once cracking or significant corrosion is present.
Internal contamination from water ingress or cross-filling with the wrong fluid requires full tank replacement rather than flushing. When specifying a replacement, confirm the capacity, mounting bracket positions, fuel pickup and return port locations, and level sender configuration. HGV fuel tanks are not universal across makes and models.
Frequently Asked Questions
Can an HGV fuel tank be repaired rather than replaced?
Minor surface corrosion on an aluminium tank can be treated, but cracks, holes, or significant corrosion around welds and fittings require replacement. Welding near a tank is hazardous and requires full emptying, purging, and gas-free certification. In most workshop situations, replacement is the safer and more practical option.
What is the difference between aluminium and plastic fuel tanks on HGVs?
Aluminium tanks are heavier and more susceptible to corrosion but are generally more robust against minor impacts. Plastic tanks are lighter and corrosion-free but can crack from stone strikes or chassis contact. Replace like-for-like unless the chassis specification allows a different material.
How do I drain an HGV fuel tank before removal?
Use a fuel transfer pump to drain the tank via the filler neck or a drain plug if fitted. Do not use compressed air to force fuel out of the tank. Fuel handling near heat sources and electrical components requires standard fire precautions.
Does Truckstop Group stock fuel tanks for all HGV makes?
We stock replacement fuel tanks for the main HGV makes including DAF, Scania, Volvo, MAN, Mercedes-Benz, Iveco, and Renault. Call us on 01527 598 000 with your chassis number to confirm availability and specification.
