Sprinter Van Auxiliary Fuel Tank: Ultimate Power

Unlock Extended Range for Your Sprinter Van: An Auxiliary Fuel Tank is Your Ultimate Power Solution for Longer Adventures.

Embarking on a long journey in your Sprinter van, whether for business or pleasure, is an exhilarating experience. However, the anxiety of fuel stops can often dampen the spirit of adventure. What if your capable Mercedes-Benz could go further, allowing you to explore more remote locations and enjoy uninterrupted travel? This is where a sprinter van auxiliary fuel tank becomes an indispensable upgrade. It’s a smart, practical solution to significantly extend your van’s range, giving you the freedom and “ultimate power” to chase horizons without constant fuel planning. Let’s explore how this system works and what benefits it offers.

Sprinter Van Auxiliary Fuel Tank: The Freedom to Explore Further

As a Mercedes-Benz enthusiast, I understand the desire to optimize every aspect of your vehicle. The Sprinter van, renowned for its capability and versatility, is a fantastic platform for exploration and work. But its standard fuel capacity, while adequate for daily driving, can sometimes feel restrictive for those grand adventures or demanding commercial routes. The concept of a sprinter van auxiliary fuel tank is elegantly simple: it’s an additional fuel storage unit that supplements your van’s primary, factory-installed tank. This means more miles between fill-ups, less time spent at gas stations, and the confidence to venture off the beaten path.

Imagine cruising through breathtaking landscapes, your eyes fixed on the road ahead, without constantly calculating your remaining fuel range. Picture a long commercial haul where multiple unscheduled fuel stops could derail your schedule. The addition of an auxiliary fuel tank elegantly solves these dilemmas, transforming your Sprinter from a capable vehicle into an even more independent and powerful explorer.

Why Consider an Auxiliary Fuel Tank for Your Sprinter?

The benefits of upgrading your Sprinter with an auxiliary fuel tank are manifold, touching upon convenience, cost-effectiveness, and enhanced capability. It’s an investment that pays dividends in freedom and efficiency, especially for those who push their vans to new limits.

Extended Range: The most obvious advantage is the ability to travel significantly further on a single outing. This is paramount for long-distance travelers, boondockers, and expedition vehicles.
Reduced Fuel Stops: Fewer trips to the pump mean more time enjoying the journey and less wasted time waiting in lines or searching for stations in remote areas.
Cost Savings (Potentially): In areas where fuel prices fluctuate dramatically, having a larger capacity allows you to fill up when prices are lower, potentially saving money over time.
Increased Payload Capacity Management: While not directly increasing payload, a larger fuel capacity can strategically distribute weight, especially when combined with other modifications.
Emergency Preparedness: In remote or unpredictable situations, having a substantial fuel reserve can be a critical lifeline, ensuring you can reach your destination or a safe haven.
Enhanced Business Efficiency: For commercial Sprinters performing long-haul routes or services in sparsely populated areas, minimizing downtime for refueling directly translates to increased productivity and profitability.

Understanding How Sprinter Van Auxiliary Fuel Tanks Work

At its core, an auxiliary fuel tank system for a Sprinter van works by integrating a secondary tank into the vehicle’s existing fuel delivery system. This is not simply a matter of bolting on an extra container; it requires a thoughtfully designed setup to ensure safe and reliable operation.

The primary components of a typical auxiliary fuel tank system include:

The Auxiliary Tank: This is a specially designed fuel-safe container, often made from durable materials like aluminum or high-density polyethylene (HDPE), with a capacity ranging from 20 to over 60 gallons, depending on the system and available space.
Fuel Pump: A dedicated electric fuel pump is usually employed to transfer fuel from the auxiliary tank to the main tank. The type and flow rate of the pump are crucial for efficient operation.
Fuel Lines: High-quality, fuel-resistant hoses and lines connect the auxiliary tank, pump, and the main fuel system.
Filtering: An integrated fuel filter is essential to ensure that any debris or contaminants from the auxiliary tank do not enter the main fuel system and harm the engine.
Transfer Control System: This can range from a simple manual switch to an automated system that monitors the main tank’s fuel level and automatically transfers fuel from the auxiliary tank when needed. Some advanced systems also monitor the auxiliary tank level to prevent overfilling and use a return-style system to manage fuel flow back to the auxiliary tank.
Mounting Hardware: Robust brackets and straps are used to securely mount the auxiliary tank, typically beneath the vehicle, ensuring it can withstand the rigors of driving.

The process generally involves the auxiliary fuel pump drawing fuel from the auxiliary tank and delivering it to the main fuel tank. This transfer can be initiated manually by the driver or automatically managed by an electronic control unit based on the main tank’s fuel level. The goal is to seamlessly integrate this extra fuel supply so that the driver experiences it as one continuous, extended fuel reservoir.

Types of Auxiliary Fuel Tank Systems

When looking to add an auxiliary fuel tank to your Sprinter, you’ll find a few common configurations and philosophies in system design. Understanding these distinctions will help you choose the best fit for your needs.

Transfer Systems: These are the most common type. They pump directly from the auxiliary tank to the main tank.
Gravity Feed: Simpler systems might rely on gravity to feed fuel, but these are less common and less precise for Sprinters, often requiring specific tank placement and venting.
Electric Pump Feed: This is the standard. An electric pump moves fuel from the auxiliary to the main tank. Control can be manual or automatic.
Replacement Systems: In some cases, a larger auxiliary tank can entirely replace the factory tank. This is less common for Sprinter vans due to chassis complexity and available space, but it provides the maximum possible fuel capacity.
Behind-the-Axle Tanks: Many aftermarket auxiliary tanks are designed to fit in the empty space over or behind the rear axle, between the frame rails. This is a popular location as it often utilizes unused real estate without significantly impacting ground clearance.
Under-Body Tanks: Similar to behind-the-axle tanks, these are mounted beneath the chassis. Careful consideration for ground clearance and durability is paramount here.

It’s important to note that the specific design and integration will vary greatly depending on the manufacturer of the auxiliary tank system and the model year of your Sprinter van. Professional installation is highly recommended to ensure everything is plumbed correctly and safely.

Key Considerations Before Installation

Before you decide to move forward with installing an auxiliary fuel tank, there are several crucial factors to consider. These will ensure you select the right system and understand the implications of such a modification.

Vehicle Model and Year: Sprinter chassis and fuel systems can vary year by year. Ensure the auxiliary tank system you choose is designed specifically for your Sprinter model and year. Manufacturers will list compatibility.
Fuel Type: Your Sprinter’s fuel type (diesel or gasoline – though most Sprinters are diesel) dictates the type of tank, pump, and seals required. Always use components designed for your specific fuel.
Installation Location and Space: Where will the tank be mounted? Underneath the van? Behind the axle? Behind the cab? Assess available space and consider its impact on ground clearance and departure/approach angles.
Fuel Capacity: How much additional fuel do you realistically need? A larger tank means more weight and takes up more space. Balance your range requirements with practicality.
System Complexity and Automation: Do you want a simple manual switch to activate the fuel pump, or do you prefer a fully automated system that manages transfer seamlessly? Automated systems offer convenience but are typically more expensive.
Material and Durability: Tanks are often made from robust materials like aluminum or HDPE. Consider the environmental conditions your van will be exposed to.
Weight: More fuel equates to more weight. Factor this into your van’s Gross Vehicle Weight Rating (GVWR) and how it might affect handling and suspension. A typical 30-gallon tank can add over 250 pounds when full.
Legal and Emissions Regulations: Inquire about local and state regulations regarding aftermarket fuel tank installations. Some regions may have specific requirements or restrictions, especially concerning evaporative emissions. Organizations like the Environmental Protection Agency (EPA) provide guidance on vehicle modifications.
Warranty Implications: Check if installing an aftermarket auxiliary tank will affect your Sprinter’s original manufacturer warranty. Some modifications might void certain aspects of your warranty.

Top Auxiliary Fuel Tank Manufacturers and Options

Several reputable companies specialize in creating high-quality auxiliary fuel tank systems for vehicles like the Sprinter van. These manufacturers focus on safety, durability, and ease of use. Here are a few well-regarded names and types of systems you might encounter:

Titan Tanks: Known for their durable, high-density polyethylene (HDPE) tanks, often designed for trucks and vans. They offer systems with advanced rollover safety valves and robust mounting.
S.J. Allen & Co. (Transfer Flow): A long-standing company producing a wide range of fuel tank systems, including extensive options for diesel applications. They emphasize quality materials and engineering.
Aerotank: Offers custom and standard fuel tank solutions, often focusing on rugged applications where durability is paramount.
In-House/Custom Solutions: Some high-end van outfitters or specialized mechanics may offer custom-fabricated aluminum tanks tailored to specific chassis and needs. These can be very effective but are often the most expensive.

When comparing systems, look at:

Feature	Description	Importance
Tank Material	Aluminum, Stainless Steel, HDPE (High-Density Polyethylene)	Durability, corrosion resistance, weight. HDPE is often lighter and resistant to impact.
Capacity (Gallons)	Common ranges: 20-60 gallons	Determines the increase in overall range.
Pump Type & Flow Rate	Electric, specific GPM (gallons per minute)	Ensures efficient and timely fuel transfer without draining power.
Control System	Manual switch, automatic sensor-based transfer	Ease of use and convenience. Automatic is generally preferred for seamless operation.
Mounting Method	Underbody, behind-axle, frame-mounted with straps/brackets	Security, clearance, and impact resistance.
Safety Features	Rollover valves, integrated filters, secure venting	Crucial for preventing leaks and ensuring safety in accidents.

Installation: Professional vs. DIY

Installing an auxiliary fuel tank system is a complex modification that involves working with critical vehicle systems. While some automotive enthusiasts are comfortable with DIY projects, this is often a job best left to professionals.

Professional Installation

Expertise: Certified mechanics or specialized van outfitters have the knowledge and experience with Sprinter chassis and fuel systems.
Tools & Equipment: They possess the specialized tools required for safe fuel line manipulation, welding (if applicable), and secure mounting.
Safety: Professionals adhere to strict safety protocols when handling fuel and working with vehicle undercarriages.
Warranty: Many installers offer a warranty on their workmanship, providing peace of mind.
Compliance: They can ensure the installation meets local legal and emissions standards.

DIY Installation

Skill Level: Requires advanced mechanical knowledge, including understanding of fuel systems, electrical wiring, and fabrication.
Tools: A comprehensive set of automotive tools, including specialty fuel line tools and potentially welding equipment, is necessary.
Time Commitment: This is not a quick afternoon project; it can take days to complete properly.
Risks: Improper installation can lead to fuel leaks, electrical shorts, engine damage, reduced vehicle performance, and significant safety hazards.
Research: Extensive research into the specific kit, the Sprinter’s fuel system, and best practices is non-negotiable. Consult resources like the National Highway Traffic Safety Administration (NHTSA) for safety recalls and guidelines related to vehicle modifications.

Given the critical nature of fuel systems and the potential safety implications, professional installation by a reputable shop specializing in Mercedes-Benz or van modifications is strongly recommended for most owners.

Maintaining Your Auxiliary Fuel Tank System

Once installed, an auxiliary fuel tank system requires some basic maintenance to ensure its continued reliable operation and longevity. Just like your primary fuel system, it needs attention.

Regular checks should include:

Visual Inspections: Periodically inspect the auxiliary tank, fuel lines, and pump for any signs of leaks, corrosion, or physical damage. Do this when you’re under the vehicle for other maintenance.
Filter Replacement: The fuel filter integrated into the auxiliary system should be replaced according to the manufacturer’s recommendations, often at intervals similar to your engine’s fuel filter.
Pump Functionality: Listen for the fuel pump during transfer. Any unusual noises or a significant decrease in transfer speed could indicate a problem.
Control System Check: Ensure your manual switch or automatic sensor system is functioning correctly. For automatic systems, check that fuel transfers as expected at appropriate fuel levels.
Tank Cleaning: Over many years, some sediment can accumulate in any fuel tank. While less common with modern diesel and filtration, periodic professional cleaning might be considered for very high-mileage vehicles.
* Fuel Additives: Using appropriate diesel fuel additives can help maintain fuel system cleanliness and prevent issues, especially for diesel Sprinters.

By performing these simple checks and maintenance tasks, you can ensure your sprinter van auxiliary fuel tank continues to provide you with the extended range and freedom you desire.

Frequently Asked Questions About Sprinter Van Auxiliary Fuel Tanks

Q1: Will adding an auxiliary fuel tank void my Sprinter’s warranty?
A1: It’s possible. Some manufacturers may consider aftermarket fuel system modifications to be grounds for voiding related warranty components. It’s wise to consult your Mercedes-Benz dealer or warranty documentation before installation.

Q2: How much extra range can I expect from an auxiliary tank?
A2: This depends on the size of the auxiliary tank and your Sprinter’s fuel economy. A common 30-gallon tank could potentially double your van’s range, but actual results will vary based on driving conditions and load.

Q3: Is it safe to have an auxiliary fuel tank installed on my Sprinter?
A3: Yes, when installed correctly by a reputable professional using quality components designed for your vehicle. Safety features like rollover valves and secure mounting are critical. Improper installation, however, can be dangerous.

Q4: How do I transfer fuel from the auxiliary tank?
A4: Most systems use an electric fuel pump. You can either activate it manually with a dashboard switch or have an automatic system in place that senses your main tank’s fuel level and transfers fuel when needed.

Q5: Can I use any type of fuel in an auxiliary tank?
A5: Absolutely not. The auxiliary tank, pump, and all associated components must be specifically designed for your Sprinter’s fuel type (e.g., diesel). Using the wrong fuel can cause severe engine damage.

Q6: Will an auxiliary fuel tank affect my Sprinter’s handling or ground clearance?
A6: Yes, to some extent. An auxiliary tank adds weight, which affects handling and suspension. Many systems are designed to minimize the impact on ground clearance by utilizing existing undercarriage space, but it’s a factor to consider.

Q7: How much does a sprinter van auxiliary fuel tank system typically cost?
A7: The cost varies widely based on tank size, system features (manual vs. automatic), brand, and whether you include professional installation. Expect to pay anywhere from $800 to $2500+ for the entire system including installation.

Conclusion: Powering Your Next Adventure with Confidence

The addition of a sprinter van auxiliary fuel tank is more than just a modification; it’s an investment in freedom, capability, and peace of mind. For those who dream of sprawling road trips, remote expeditions, or simply more efficient commercial operations, this upgrade transforms the already remarkable Sprinter into a vehicle with truly boundless potential. By extending your range, reducing interruptions, and providing the confidence to travel without constant fuel anxiety, you unlock a new level of adventure and utility.

Remember, selecting the right system and ensuring professional, safe installation are paramount. With careful consideration of your needs and thorough research, you can find a high-quality auxiliary fuel tank solution that perfectly complements your Sprinter van. Embrace the open road, explore further, and enjoy the ultimate power that comes with knowing your Sprinter is ready for any journey, no matter how long. Your next great adventure awaits, fueled and ready.