Mitsubishi Montero (2004+). Manual - part 1143

SPECIAL TOOLS

TSB Revision

FUEL SUPPLY

13B-5

SPECIAL TOOLS

M1135000600322

TOOL

TOOL NUMBER AND 
NAME

SUPERSESSION

APPLICATION

MB991958

A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991914
F: MB991825
G: MB991826

MUT-III sub assembly

A: Vehicle 

Communication 
Interface (V.C.I.)

B: MUT-III USB cable
C: MUT-III main harness 

A (Vehicles with CAN 
communication 
system)

D: MUT-III main harness 

B (Vehicles without 
CAN communication 
system)

E: MUT-III main harness 

C (for Daimler Chrysler 
models only)

F: MUT-III measurement 

adapter

G: MUT-III trigger 

harness

MB991824-KIT
NOTE: G: MB991826 
MUT-III trigger harness is 
not necessary when 
pushing V.C.I. ENTER 
key.

• Reading diagnostic 

trouble code

• MFI system inspection

CAUTION

MUT-III main harness B 
(MB991911) should be 
used. MUT-III main 
harness A and C should 
not be used for this 
vehicle.

MB991348 Test harness 
set

MB991348-01

Fuel tank differential 
pressure sensor check

MB991910

MB991826

MB991958

MB991911

MB991914

MB991824

MB991827

MB991825

DO NOT USE

A

B

C

D

E

F

G

DO NOT USE

MB991348

ON-VEHICLE SERVICE

TSB Revision

FUEL SUPPLY

13B-6

ON-VEHICLE SERVICE

FUEL LEVEL SENSOR CHECK

M1135003100393

Refer to GROUP 54A 

P.54A-74

.

FUEL LEVEL SENSOR REPLACEMENT

M1135001400150

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

located under the second seat.

3. Remove the second seat, the rear scuff plate, the anchor 

bolts for the outer seat belt (second) and mounting screws of 
the lower quarter trim. Tear off the carpet. (Refer to GROUP 
52A 

P.52A-19

.)

4. Remove the service hole cover and the packing located 

between the front seat and the second seat.

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-19

.)

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.13A-998

.

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.

ACX00759 AB

ACX00218 AJ

SERVICE HOLE (UPPER)

SERVICE HOLE (LOWER)

ON-VEHICLE SERVICE

TSB Revision

FUEL SUPPLY

13B-7

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.

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-8

FUEL TANK

REMOVAL AND INSTALLATION

M1135001900531

Pre-removal Operation
• Draining Fuel

• Fuel Line Pressure Reduction (Refer to GROUP 13A 

P.13A-998

.)

• 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)