Multi-walled carbon nanotubes (MWCNTs), which are one of the most favorable large aspect ratio hollow-cylindrical nanomaterials, have been considered for numerous advanced applications due to their exceptional thermal-mechanical and electrical characteristics. However, because of the high surface area and being susceptible to agglomeration, they suffered from low dispersion ability. Thus, functionalization with organic and inorganic materials is one of the promising solutions to their limitations. Due to the presence of sp2-bonded carbon atoms, they have no functionalities. One way to generate carboxylic functionalities on MWCNTs is their oxidation. Herein, this study reports the synthesis of a novel highly-oxidized multi-walled carbon nanotube (O-MWCNT) particles modified by the polyaniline (PANI) nanofibers and their performance in the epoxy-based nanocomposites for achieving passive/active anti-corrosion system with efficacious self-healing potency and barrier anti-corrosion characteristic. The O-MWCNT-PANI nanocomposite was then modified by the zinc metal cations to accomplish a smart self-healing anti-corrosion system. The total resistance of about 4000 ohm.cm2 was achieved in the extract with O-MWCNT-PANI-Zn, while the blank sample showed a resistance of about 1200 ohm.cm2 after three hours of immersion time. The most noticeable enhancement of the dual active-barrier protection was obtained in the scratched coatings with modified nano-inhibitors. The more log|Z|10 mHz values were reached, including 4.82 ohm.cm2 and 5.06 ohm.cm2, in O-MWCNT-PANI/EP and O-MWCNT-PANI-Zn/EP, respectively.