Mitsubishi Montero (2002-2004). Manual - part 1070

FUEL TANK

TSB Revision

FUEL SUPPLY

13B-13

AC101598AB

31

30

39

46

45

44

38

49

48

47

35

36

34

33

32

37

40

43

42

41

REMOVAL STEPS

30. FUEL CAP
31. FUEL TANK FILLER TUBE 

PROTECTOR

32. FUEL FILLER HOSE
33. FUEL TANK FILLER TUBE 

BREATHER HOSE

34. FUEL TANK FILLER TUBE VAPOR 

HOSE

35. FUEL TANK FILLER TUBE VAPOR 

HOSE

36. FUEL TANK FILLER TUBE VAPOR 

HOSE

37. FUEL TANK LEVELING PIPE 

ASSEMBLY

38. FUEL TANK FILLER TUBE
39. FUEL TANK FILLER TUBE GASKET
40. FUEL TANK FILLER TUBE VAPOR 

HOSE

41. FUEL TANK FILLER TUBE VAPOR 

HOSE

42. FUEL TANK FILLER TUBE VAPOR 

HOSE

43. FUEL TANK FILLER TUBE VAPOR 

HOSE

44. FUEL TANK FILLER TUBE VAPOR 

HOSE

45. FUEL CHECK VALVE ASSEMBLY
46. FUEL TANK FILLER TUBE VAPOR 

HOSE

47. FUEL TANK FILLER TUBE VAPOR 

HOSE

48. >FUEL CHECK VALVE ASSEMBLY
49. FUEL TANK FILLER TUBE VAPOR 

HOSE

REMOVAL STEPS (Continued)

FUEL TANK

TSB Revision

FUEL SUPPLY

13B-14

Required Special Tool:
MB991348: Test Harness Set

REMOVAL SERVICE POINTS

.

<<A>> FUEL HIGH-PRESSURE HOSE REMOVAL

CAUTION

As there will be some pressure remaining in the fuel pipe 
line, cover it with a shop towel to prevent fuel from spray-
ing out.
Press the high-pressure fuel hose retainer to disengage the 
connector, and then remove the high-pressure fuel hose.

.

<<B>> DISCONNECTION OF FUEL TANK BREATHER 
HOSE/DISCONNECTION OF FUEL TANK HARNESS 
CONNECTOR
Lower the fuel tank halfway to disconnect the fuel tank breather 
hose and the fuel tank harness connector.

INSTALLATION SERVICE POINT

.

>>A<< FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION

After connecting the quick action joint of the fuel high-
pressure hose, pull the joint to disconnecting direction 
lightly to check that it is mounted securely. In addition, at 
this time confirm that there is a play of approx. 3 mm (0.12 
inch) at the joint.

INSPECTION

M1135002000199

FUEL SHUT-OFF VALVE CHECK

Check that the flapper and valve open and close as shown in 
the illustration.

ACX00763

RETAINER

O-RING

NYLON TUBE

FUEL PIPE

SPOOL

CONNECTOR

O-RING

AB

AC005004AB

CLOSED

OPEN

FLAPPER

80˚

FUEL TANK

TSB Revision

FUEL SUPPLY

13B-15

FUEL TANK ROLLOVER VALVE ASSEMBLY 
CHECK

1.  Shake the fuel tank rollover valve assembly up and down to 

check if the float inside the fuel tank rollover valve assembly 
is not seized. If seized, replace the fuel tank rollover valve 
assembly.

2.  Obtain a container, which is full of water.
3.  Invert the fuel tank rollover valve assembly, and submerge it 

slowly in the water while placing your fingers over the 
nozzle.

4.  Check that no more air bubbles appears from the fuel tank 

rollover valve assembly, and withdraw it slowly.

5.  Open the fuel tank rollover valve assembly nozzle. If no 

water flows out from the nozzle aperture, the valve is 
normal. If water flows out, the float or spring inside the fuel 
tank rollover valve is defective. Replace the fuel tank rollover 
valve assembly.

ACX00760AB

AC102262

NOZZLE

AB

AC102263

<NORMAL>

<DEFECTIVE>

AB

FUEL TANK

TSB Revision

FUEL SUPPLY

13B-16

FUEL PUMP (MODULE) DISASSEMBLY AND ASSEMBLY

M1135004600023

ASSEMBLY SERVICE POINT

.

>>A<< O-RING / GROMMET INSTALLATION
Apply gasoline on the O-ring and the grommet before mounting 
them to prevent damage or twisting.

ACX01537

10

11

9

8

6

7

4

5

3

2

1

AB

N

DISASSEMBLY STEPS

1. FUEL PUMP BRACKET
2. FUEL PUMP CUSHION
3. FUEL PUMP

>>A<<

4. GROMMET
5. PUMP HARNESS
6. HOUSING

7. ASSIST PUMP
8. CAP

>>A<<

9. O-RING
10. FUEL TANK DIFFERENTIAL 

PRESSURE SENSOR

11. FUEL HIGH-PRESSURE FILTER

DISASSEMBLY STEPS (Continued)