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Owl Sprinter Van Tech Series: Extended Fuel Tanks

How to get more range out of your Sprinter based overland van with extended range fuel tanks. 

 

Owl Extended Range Fuel Tanks

 

Our video discusses the significant benefits of upgrading a van’s fuel system, especially focusing on the installation of an oversized or long-range fuel tank and a specialized fuel filler nozzle. John contrasts a standard factory fuel tank, which typically holds around 23 gallons, with a much larger tank that can hold approximately 45 to 47 gallons. This upgrade is especially valuable for long road trips where frequent refueling can be inconvenient, costly, or impossible due to remote gas stations with high prices. By increasing fuel capacity, travelers can reduce stops, save money, and gain peace of mind on extended journeys.

Additionally, the video highlights the importance of upgrading the fuel filler nozzle. Standard U.S. diesel nozzles are smaller and often incompatible with the larger nozzles found at truck stops or in other countries like Mexico and Canada. The upgrade to a “rest of world” Mercedes fuel filler nozzle removes the locking door on the fuel filler, making it easier to fill the tank and allowing the use of larger nozzles without adaptations. This is particularly useful for international travel or for using truck stop facilities designed for larger vehicles.

Fuel tank and suspension upgrades are two of the most impactful modifications for van travelers. Ultimately, these upgrades improve the overall travel experience by addressing fuel capacity limitations and fueling convenience.

Highlights

  •  Long-range fuel tanks significantly increase fuel capacity, allowing fewer stops on long trips.
  •  Factory fuel tanks generally hold about 23 gallons; upgraded tanks can hold up to 47 gallons.
  •  Larger fuel tanks can save money by enabling fills in cheaper, more convenient locations.
  •  Specialized Mercedes “rest of world” fuel filler nozzles allow use of larger diesel nozzles internationally.
  •  Upgrading the fuel filler nozzle removes the locking door, simplifying fueling at truck stops.
  •  Always check for sufficient under-vehicle space before installing a larger fuel tank.
  •  Fuel tank and suspension upgrades are among the most transformative modifications for van travelers.

Key Insights

  •  Fuel tank capacity is a critical limiting factor for van travel: The standard factory fuel tanks, typically around 23 gallons, limit the distance you can travel without refueling. For vehicles that do not have great fuel economy, this means frequent stops, which can disrupt long-distance travel plans. Upgrading to a long-range fuel tank nearly doubles the capacity, offering a substantial increase in travel range and convenience.

  •  Cost savings through strategic refueling become possible with a larger tank: Fuel prices vary widely by region, with remote areas and certain states like California often charging premium prices. By having a larger tank, travelers can fill up in cheaper locations before entering expensive regions, resulting in significant savings over time. This makes the upgrade cost-effective as the initial investment is recouped through avoided high fuel costs.

  •  Compatibility with international fueling infrastructure is crucial for border-crossing travelers: The standard U.S. diesel nozzles are smaller, and truck stops or fuel stations in Mexico, Canada, or other countries use larger nozzles to fill bigger tanks on commercial vehicles. The upgraded “rest of world” Mercedes fuel filler nozzle facilitates filling with these larger nozzles, avoiding the need for awkward adapters or funnels.

  •  Removing the locking door on the fuel filler nozzle enhances usability: Factory fuel filler nozzles on vehicles like Sprinters feature a locking door that requires manual intervention to open if the nozzle size does not match perfectly. This can be cumbersome and inconvenient, especially in foreign countries. The upgraded nozzle eliminates this locking door, improving ease of use and reducing frustration during fueling.

  •  Vehicle compatibility and installation considerations are vital: Before upgrading to an oversized fuel tank, it’s essential to inspect the available space under the vehicle to ensure proper fitment. Custom van builds and different vehicle models (Revel, Storyteller, Sprinter, etc.) may have varying clearance, meaning not every vehicle can accommodate larger tanks without modifications.

  •  Fuel system upgrades rank among the most impactful modifications for van life: Along with suspension upgrades, increasing fuel capacity dramatically improves the travel experience by enabling longer trips without interruption and better handling of rough roads or heavy loads. Many van owners report that once these upgrades are installed, they wonder how they ever managed without them.

  •  Practical benefits extend beyond convenience to include time savings and reduced stress: Long road trips can be exhausting, and the constant need to stop for fuel adds to travel time and fatigue. Larger tanks and improved fueling hardware allow for smoother journeys, less time spent searching for compatible gas stations, and reduced anxiety about running low on fuel in remote areas.

In summary, upgrading a van’s fuel system with a larger capacity tank and a more versatile fuel filler nozzle is a strategic enhancement for serious travelers. It improves range, lowers costs, simplifies fueling logistics, and supports international travel, all while significantly enhancing the overall van life experience.