Mitsubishi Montero (2002-2004). Manual - part 1069

ON-VEHICLE SERVICE

TSB Revision

FUEL SUPPLY

13B-9

5. Disconnect the harness connector.
6. Unscrew the mounting nut to remove the fuel level sensor.
7. Assemble the fuel level sensor and tighten the mounting nut 

to the specified torque.

Tightening torque: 2.5 

± 0.4 N⋅m (22 ± 4 in-lb)

8. Connect the harness connector.
9. Attach the service hole cover and the packing located 

between the front seat and the second seat.

10.Restore the carpet; attach the second seat, the rear scuff 

plate, anchor bolts for the outer seat belt (second) and 
mounting screws of the lower quarter trim. (Refer to GROUP 
52A 

P.52A-18

.)

11.Attach the service hole cover located under the second seat 

and the packing.

12.Restore the second seat.

FUEL PUMP OPERATION CHECK

M1135001000033

Refer to GROUP 13A - On-vehicle Service 

P.13Aa-16

.

FUEL PUMP MODULE REPLACEMENT

M1135004900013

1. Tumble the second seat.
2. Remove the service hole cover (upper side) and the 

packing.

3. Remove the service hole cover (lower side) and the packing.
4. Disconnect the harness connector.
5. Disconnect the fuel high-pressure hose and the fuel tank 

hose.

6. Unscrew the mounting nut to remove the fuel pump module.
7. Assemble the fuel pump module and tighten the mounting 

nut to the specified torque.

Tightening torque: 2.5 

± 0.4 N⋅m (22 ± 4 in-lb)

8. Connect the fuel high-pressure hose and the fuel tank hose.
9. Connect the harness connector.
10.Attach the service hole cover (lower side) and the packing. 
11.Attach the service hole cover (upper side) and the packing.
12.Restore the second seat.

ACX00759AB

ACX00218 AJ

SERVICE HOLE (UPPER)

SERVICE HOLE (LOWER)

ON-VEHICLE SERVICE

TSB Revision

FUEL SUPPLY

13B-10

FUEL TANK DIFFERENTIAL PRESSURE SENSOR 
CHECK

M1135003200033

1. Tumble the second seat.
2. Remove the service hole cover (upper) and packing.
3. Remove the service hole cover (lower) and packing.
4. Disconnect the harness connector.

5. Disconnect the fuel tank differential pressure sensor 

connector and connect special tool MB991348 between the 
terminals of the disconnected connector.

6. Turn the ignition switch to "ON" and take a reading of 

Between terminals (2) and (3).

Standard value: 2.0 

− 3.0 V

LEVELING VALVE CHECK

M1135004300077

1.  Place a drain pan, and disconnect the fuel tank filler tube 

breather hose at pipe side. 
NOTE:  If fuel leaks from the fuel tank filler tube breather 
hose at this stage, the leveling valve may be defective.

2.  Open the fuel cap, and fill the fuel tank up.
3.  If fuel does not leak from the fuel tank filler tube breather 

hose with the fuel tank full, the leveling valve is normal. If not 
so, the leveling valve may be defective. Lower the fuel tank 
from the vehicle and replace the valve.

4.  Reconnect the fuel tank filler tube breather hose at the pipe 

side. 

ACX00218 AJ

SERVICE HOLE (UPPER)

SERVICE HOLE (LOWER)

ACX00762 AB

MB991348

AC102445AC

FUEL TANK FILLER TUBE
BRETHER HOSE

FUEL TANK

TSB Revision

FUEL SUPPLY

13B-11

FUEL TANK

REMOVAL AND INSTALLATION

M1135001900274

Pre-removal Operation
• Draining Fuel

• Fuel Line Pressure Reduction (Refer to GROUP 13A 

P.13Aa-15

.)

• Transmission Mount Center Member Assembly (Refer to 

GROUP 32 

P.32-6

.)

Pre-installation Operation
• Transmission Mount Center Member Assembly (Refer to 

GROUP 32 

P.32-6

.)

• Fuel Leakage Inspection

• Refilling Fuel

AC101596AB

9

12

8

10

1

2

3

4

5

6

7

11

14

13

26 ± 4 N·m
19 ± 3 ft-lb

26 ± 4 N·m
19 ± 3 ft-lb

26 ± 4 N·m
19 ± 3 ft-lb

21 ± 4 N·m
16 ± 2 ft-lb

N

REMOVAL STEPS

1. FUEL TANK UNDER COVER
2. FUEL FILLER HOSE CONNECTION
3. FUEL RETURN HOSE 

CONNECTION

4. FUEL VAPOR HOSE CONNECTION

<<A>> >>A<<

5. FUEL HIGH-PRESSURE HOSE 

CONNECTION

6. FUEL TANK BAND FRONT
7. FUEL TANK BAND REAR

<<B>>

8. FUEL TANK FILLER TUBE 

BREATHER HOSE CONNECTION

<<B>>

9. FUEL TANK HARNESS 

CONNECTOR CONNECTION

10. FUEL TANK FILLER TUBE PURGE 

HOSE CONNECTION

11. FUEL TANK FILLER TUBE VAPOR 

HOSE A CONNECTION

12. FUEL TANK FILLER TUBE VAPOR 

HOSE C CONNECTION

13. FUEL TANK ASSEMBLY
14. FUEL TANK FILLER TUBE VALVE

REMOVAL STEPS (Continued)

FUEL TANK

TSB Revision

FUEL SUPPLY

13B-12

AC101597

2.5 ± 0.4 N·m
22 ± 4 in-lb

18

26

27

2.5 ± 0.4 N·m
22 ± 4 in-lb

21

22

25

N

N

2.5 ± 0.4 N·m
22 ± 4 in-lb

2.5 ± 0.4 N·m
22 ± 4 in-lb

23

24

28

29

20

15

16

AB

17

19

REMOVAL STEPS

15. FUEL RETURN HOSE
16. FUEL VAPOR HOSE 
17. FUEL HIGH-PRESSURE HOSE
18. FUEL TANK VAPOR HOSE 
19. FUEL TANK ROLLOVER VALVE
20. FUEL TANK SUCTION HOSE
21. FUEL TANK RETURN HOSE
22. FUEL TANK HARNESS

23. TAPPING PLATE
24. FUEL PUMP MODULE ASSEMBLY
25. PACKING
26. FUEL LEVEL SENSOR
27. PACKING
28. FUEL TANK LEVELING VALVE 

ASSEMBLY

29. FUEL TANK

REMOVAL STEPS (Continued)