Mitsubishi Montero (2004+). Manual — part 1143

SPECIAL TOOLS

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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

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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

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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

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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)