Mopar B-Body Fuel Tank: Plastic Replacement Options

Mopar fuel tanks are available in Poly, Alloy Coated Steel, and Stainless Steel. They are compatible with a range of models, including the 1933-1990 Dodge and Plymouth, and the 1968-1970 B-Body. There are also options for fuel injection tanks, which are compatible with classic Mopar models. When replacing a fuel tank, it is important to consider the type of fuel pump and sending unit, as well as the compatibility of the filler neck and grommet.

Plastic vs metal fuel tanks

Fuel tanks are generally made of either metal or plastic high-density polyethylene (HDPE). Each material has its own advantages and disadvantages, so it's important to consider your specific needs and budget when selecting a fuel tank.

Durability

Metal fuel tanks are incredibly strong and resilient, able to withstand harsh weather conditions, external damage, fire, and explosions. This makes them ideal for industrial settings and long-lasting use. On the other hand, plastic tanks are more susceptible to damage from UV exposure, extreme temperatures, and harsh weather conditions. However, plastic tanks are lightweight, making them easier to transport and install.

Cost

Plastic tanks are typically more affordable upfront due to the lower cost of the material and easier production process. Metal tanks often require more specialized equipment and processes for manufacturing, driving up the initial cost. However, metal tanks may be more cost-effective in the long run due to their longer lifespan.

Maintenance

Both types of tanks require regular maintenance. Metal tanks need regular cleaning, painting, and protection against corrosion and rust. Plastic tanks are lower maintenance, requiring only cleaning to remove debris and sediment. Plastic tanks are also less likely to develop leaks, reducing the risk of fuel contamination.

Environmental Impact

Metal tanks can be more challenging to recycle and may have a larger carbon footprint than plastic tanks. Plastic tanks are lightweight and easier to recycle, making them a more environmentally friendly option. However, some areas prohibit the use of plastic tanks for certain types of fuel, such as diesel.

Flexibility

Plastic tanks can be formed into complex shapes, allowing for space-saving installations. Metal tanks, while having made manufacturing breakthroughs, are not as flexible and customizable as plastic tanks.

Safety

Metal tanks are generally considered safer in the event of a fire, as they can withstand high temperatures and are less likely to succumb or explode, according to the American Iron and Steel Institute. Plastic tanks, being made of softer material, may melt and cause fuel leaks that can add to the flames.

Corrosion Resistance

Metal tanks are susceptible to corrosion and rust, especially when exposed to salt, gravel, and other debris. Water vapors can also build up inside metal tanks when they are not completely full, leading to internal rusting. Plastic tanks, such as polyethylene tanks, are not affected by corrosion and will have longer useful lives as a result.

Both plastic and metal fuel tanks have their advantages and drawbacks. Plastic tanks offer benefits such as flexibility, lightweight construction, corrosion resistance, and cost-effectiveness, while metal tanks provide superior durability, safety, and reliability. It is essential to carefully consider your specific requirements, budget, and applicable regulations before making a decision.

Fuel tank leaks

There are several common causes of fuel leaks. One of the most common is a worn or damaged fuel tank. Over time, the walls of the tank can become thin and brittle, leading to holes and cracks. This can be caused by exposure to the elements, such as sun and rain, or by physical damage from an accident. If you suspect that your fuel tank is damaged, it is important to have it inspected by a professional as soon as possible.

Another common cause of fuel leaks is faulty fuel lines. Fuel lines carry gasoline from the tank to the engine, and if they become cracked or damaged, they can leak gasoline onto the ground or into the engine compartment. This can be a fire hazard and can damage the engine. Fuel lines should be inspected regularly for signs of wear and tear.

Leaking fuel injectors are another potential cause of fuel leaks. Fuel injectors deliver gasoline to the engine, and over time, they can become clogged with dirt and debris, causing them to leak. If you notice that your fuel injectors are leaking, it is important to have them cleaned or replaced as soon as possible.

The fuel pump is another component that can cause fuel leaks. The pump draws gasoline from the tank and delivers it to the engine. If the pump becomes damaged, it can leak gasoline onto the ground or into the engine compartment, creating a fire hazard and potentially damaging the engine. Regular inspections of the fuel pump for signs of wear and tear are recommended.

A bad gas cap can also lead to fuel leaks. The gas cap seals the fuel tank and prevents gasoline from leaking out. If the gas cap is damaged or not properly sealed, it can allow gasoline to escape. It is important to inspect your gas cap regularly to ensure it is in good condition.

In the event of a fuel leak, it is recommended to have your vehicle inspected by a professional as soon as possible. Taking care of the issue promptly can save you money in repairs and help keep you safe.

Fuel tank installation

Step 1: Choose the Right Fuel Tank

Select a fuel tank that is compatible with your vehicle, in this case, a Mopar B-body plastic replacement fuel tank. Ensure that the tank is made of high-quality materials, such as high-density polyethylene (HDPE), which is known for its durability and impact resistance.

Step 2: Prepare the Installation Site

Choose a safe location for the fuel tank installation, preferably on firm, level ground, away from potential hazards and environmental risks such as flooding. The site should also be away from any residential or office buildings. It is important to refer to local regulations and carry out risk assessments to ensure compliance with health and safety standards.

Step 3: Gather Necessary Equipment

Ensure that you have all the necessary equipment for the installation, including safety response products such as powder, foam, clay covers, or absorbent granules in case of spills or leaks. Additionally, have a technician verify that your fuel tank is functioning properly and that all components, such as the vent valve, are in good condition.

Step 4: Position the Fuel Tank

Place the fuel tank in the designated location, ensuring that it is level and secure. If your fuel tank has metal legs, adjust them to provide a slight slant to accommodate the valve and filter. Make sure there is sufficient space around the tank for maneuverability and quality inspection.

Step 5: Install Safety Features

Install a vent alarm or vent whistle at the top of the tank to prevent overflows. This whistle will sound while the tank is being filled and stop when it is almost full. Additionally, install an oil gauge to monitor the fuel level in the tank. Use pipe thread sealant to secure these components to your tank.

Step 6: Connect the Fuel Lines

Identify the fill line and vent line holes, typically located opposite the supply connection line. Remove the caps from these holes and connect the appropriate piping. The fill pipe, which is used to fill the tank, should be galvanized steel, about two inches wide, and run outdoors near the foundation of the building. Similarly, a vent pipe should run outdoors from the vent line hole, with a width of 1.25 inches and capped at the end.

Step 7: Install the Oil Filter and Shutoff Valve

In the front base of the fuel tank, opposite the piping connections, install the oil filter and shutoff valve to the supply line. The shutoff valve will stop the fuel flow in case of any issues, and the oil filter will ensure that the fuel is clean and free of contaminants.

Step 8: Connect the Supply Line

Connect the supply line to the oil filter and compression fitting. Route the supply line along the perimeter of the walls or the basement, providing protection with polyethylene-coated copper piping. Finally, connect the supply line to the engine or furnace, ensuring all connections are sealed with pipe thread sealant to prevent leaks.

Step 9: Final Checks and Testing

Once the installation is complete, perform a final inspection to ensure that all connections are secure and all safety features are functioning properly. Refer to the manufacturer's instructions for any specific recommendations or requirements for your Mopar B-body plastic replacement fuel tank. Finally, fill the tank to the recommended capacity, typically around 95%, and test the system to ensure proper functioning.

Fuel tank maintenance

Preventing Contamination

Fuel tanks can accumulate dirt, rust, and other contaminants over time, which can mix with the fuel and cause engine problems. It is important to use quality fuel from reputable fuel stations and regularly check for leaks that could lead to contamination.

Extending Equipment Life

Regular cleaning and maintenance help preserve the integrity of the fuel tank and related components, ultimately extending the life of your equipment. This includes the fuel pump and injectors, which can be damaged by sludge and debris.

Ensuring Efficiency

A clean fuel tank ensures smooth fuel flow, preventing blockages and maintaining optimal performance. Contaminants can cause blockages and restrict fuel flow, making the engine work harder and consume more fuel, leading to decreased fuel efficiency.

Avoiding Costly Repairs

Neglecting fuel tank inspection and cleaning can lead to severe damage and expensive repairs or replacements. Regular maintenance can help identify issues early on and prevent them from escalating.

Regular Fuel Tank Inspection

Conduct regular fuel tank inspections to detect contamination early. Use a flashlight and mirror to look for signs of rust, sludge, or water in the tank. It is recommended to inspect your tank every six to twelve months, depending on your operations.

Professional Fuel Tank Cleaning

Hire a professional fuel tank cleaning service to ensure your tank is thoroughly cleaned and free of contaminants. Experts use specialized equipment and techniques to restore your tank to optimal condition.

Fuel Additives

Use fuel additives to help prevent the buildup of contaminants. These additives are designed to clean the fuel system and improve performance, but they should not be relied on as a substitute for regular maintenance and cleaning.

Fuel Filter Replacement

Regularly replace the fuel filter to maintain a clean fuel system. A clean filter can effectively trap impurities, preventing them from reaching the engine. Follow the manufacturer's recommendations for filter replacement schedules.

Additionally, it is important to check fuel levels and quality. Poor-quality fuel can damage your tank and equipment, leading to potential downtime and costly repairs. Keep the area around your tank clear of debris and vegetation to easily identify any leaks, drips, or spills. Finally, inspect the pumping equipment, vents, valves, and hinges for any signs of wear and tear, and lubricate or replace them as needed.

Fuel tank accessories

Fuel Tank Caps

Fuel tank caps are crucial for sealing the fuel tank and preventing fuel leakage. They also help maintain the optimal pressure within the tank and prevent dust, debris, and moisture from contaminating the fuel. Caps can be made from various materials, including plastic and metal, and often feature a locking mechanism for added security.

Fuel Sending Units

Fuel sending units are responsible for monitoring the fuel level in the tank and relaying this information to the fuel gauge. They typically consist of a float attached to a rod, which moves up and down with the fuel level, providing an accurate reading. Sending units are essential for helping drivers keep track of their fuel levels and plan refuelling stops accordingly.

Fuel Pump and Sending Unit

The fuel pump plays a critical role in delivering fuel from the tank to the engine. It generates the necessary pressure to push the fuel through the lines to the engine's fuel injectors. The sending unit, in conjunction with the fuel pump, ensures that the engine receives a steady and controlled supply of fuel, optimizing engine performance.

Fuel Lines and Tubes

Fuel lines and tubes are essential conduits that transport fuel from the tank to the engine. They are typically made of durable materials, such as rubber or metal, and are designed to withstand high fuel pressures. These lines and tubes must be securely connected to the tank and engine to prevent leaks and ensure uninterrupted fuel flow.

Fuel Tank Straps

Fuel tank straps are metal or plastic fasteners that secure the fuel tank in place, typically within the vehicle's chassis. They help to stabilize the tank, preventing it from shifting or moving during vehicle operation. Fuel tank straps also provide an additional layer of protection, reducing the risk of damage to the tank in the event of an impact or collision.

Fuel Filler Necks and Doors

Fuel filler necks are the openings through which fuel is added to the tank. They are typically located on the exterior of the vehicle and are connected to the fuel tank by a hose or tube. Filler necks may have a door or cover to protect the opening when not in use, preventing dust and debris from entering the tank.

Frequently asked questions