Mitsubishi L200. Manual - part 205

GENERAL INFORMATION

FUEL SUPPLY

13B-2

GENERAL INFORMATION

M1135000100725

Fuel tank is mounted on the front of the rear axle to 
reduce the shock at impact. A fuel cut valve, which 
prevents fuel leakage when the vehicle banks or rolls 
over, has been located inside the fuel tank for fewer 
openings and hose bonding points on the fuel tank 
top surface.

SPECIAL TOOLS

M1135000601143

Tool

Number

Name

Use

B992145

MB992145

Fuel leak check cap

Fuel leak check

B992264

MB992264

Fuel hand pump

Fuel draining

B992265

MB992265

Fuel hose adaptor A

B992266

MB992266

Fuel hose adaptor B

ON-VEHICLE SERVICE

FUEL LEAK CHECK OF FUEL TANK

M1135005900566

CAUTION

Always check the fuel leak of fuel tank with the 
vehicle loaded. If it is checked with the fuel tank 
removed, the fuel tank may be damaged.

AC600149

MB992145

AC

ON-VEHICLE SERVICE

FUEL SUPPLY

13B-3

1. Remove the fuel tank cap, install special tool fuel 

leak check cap (MB992145).

AC600150

MB992145

Pressure 
gauge

Trigonal joint

Hose blocking plier

Air gun

AB

2. Install the hose and pressure gauge to the special 

tool (MB992145) as shown.

AC711418AC

Fuel filler
neck

Hose
blocking
plier

Rear tire (LH)

Fuel tank hose

3. Remove the splash shield rear (LH) (Refer to 

GROUP 42 

− Splash Shield ), and block the fuel 

tank hose.

CAUTION

• Do not pressurize suddenly.
• Do not pressurize 11.76 kPa or more to pre-

vent the damage of components.

4. Pressurize while checking the pressure gauge 

and hold if it reaches from 9.80 to 11.76 kPa.

5. Leave it for approximately 3 minutes and check 

that the pressure is not weakened.

6. If the pressure is weakened, apply soapy water to 

each part with pressurized state and check the 
leak while confirming if air bubbles are seen.

FUEL DRAINING

M1135006900321

CAUTION

• Working area should be airy and kept from 

flame.

• Prepare a fire extinguisher before working.
• Install the earth lines to the vehicle and fuel 

tank to prevent static electricity, and water the 
work place to keep the footing from slipping.

• Touch the vehicle with hands to release the 

charged static.

•

AC711661

Fuel hose

Fuel pipe

AB

Keep the drained fuel in the safety place.

1. Disconnect the fuel pipe on the side of fuel tank 

from the fuel hose on the front side of fuel tank.

AC711667

Fuel hose

AB

Fuel hose
(bore: 

 

7.6 mm)

MB992264

MB992265

2. Connect the special tools fuel hand pump 

(MB992264), fuel hose adaptor A (MB992265) 
and two fuel hoses (Inner diameter 7.6 

± 0.4 mm) 

to the disconnected fuel hose.

3. Operate the special tool (MB992264) to drain fuel 

from the fuel tank.

FUEL TANK

FUEL SUPPLY

13B-4

FUEL TANK

REMOVAL AND INSTALLATION

M1135001902913

Pre-removal and Post-installation Operation
• Rear Splash Shield (LH) Removal and Installation (Refer 

to GROUP 42 

− Splash Shield ).

AC805923 AB

2.5 ± 0.4 N·m

7

9

10

4

5

11

12

17

16

15

18

19

20

14

13

8

N

6

6

N

N

1

2

3

55 ± 3 N·m

55 ± 3 N·m

Fuel tank removal steps 

1.

Fuel filler hose connection

2.

Vapour hose connection

3.

Levelling hose connection

4.

Fuel return pipe connection

5.

Fuel main pipe connection

<<

A

>>

>>

A

<<

6.

Self-locking nut

<<

A

>>

7.

Fuel gauge unit connector and 
harness clamp 

<<

A

>>

8.

Fuel tank assembly

9.

Fuel return hose

10. Fuel main hose

11. Fuel gauge unit
12. Packing
13. Front lower protector
14. Fuel tank

Fuel filler neck removal steps 

15. Fuel filler hose
16. Vapour hose
17. Levelling hose
18. Fuel filler cap
19. Fuel filler neck
20. Packing

Fuel tank removal steps 

FUEL TANK

FUEL SUPPLY

13B-5

REMOVAL SERVICE POINT

<<A>> SELF-LOCKING NUT/FUEL GAUGE UNIT 
CONNECTOR AND HARNESS CLAMP/FUEL 
TANK ASSEMBLY REMOVAL

CAUTION

Be careful not to open circuit in the harness 
when removing the fuel tank assembly.

AC504246

Fuel tank assembly

Transmission jack

AB

1. Support the fuel tank assembly using the 

transmission jack, and remove self-locking nuts.

2. Using the transmission jack while taking care of 

the fuel harness, lower the fuel tank assembly 
until the fuel harness installation position over the 
fuel tank assembly can be checked.

3. Disconnect fuel gauge unit connector, and 

harness clamp. Then, remove the fuel tank 
assembly.

INSTALLATION SERVICE POINT

>>A<< SELF-LOCKING NUT INSTALLATION

AC505408

Fuel tank

Self-locking nut

Front lower protector 
or reinforcement part

AC

CAUTION

When tightening the self-locking nut, be careful 
not to let the nut touch the bent part of the rein-
forcement of the fuel lower protector and the fuel 
tank.

DISASSEMBLY AND REASSEMBLY

M1135051100251

FUEL GAUGE UNIT 

AC611598AB

1

2

Disassembly steps 

1.

Fuel in-tank filter

2.

Fuel tank gauge

FUEL GAUGE UNIT CHECK

M1135003100586

Refer to GROUP 54A 

− On-vehicle Service, Fuel 

Gauge Unit Check .