So your Gen3 Montero is leaking fuel when parked uphill, going up an obstacle or when it is hot outside?

ChrisCosta416

Well-known member
Today we will be going over a Technical Service Bulletin (TSB)/Recall Issued my Mitsubishi Motors back in August of 2004. Technical Service Bulletins are issued by a vehicle manufacturer when there are several occurrences of an unanticipated problem. In this case a fuel leak. A recall is issued when a manufacturer or NHTSA determines that a vehicle, equipment, car seat, or tire creates an unreasonable safety risk or fails to meet minimum safety standards.

THIS WILL BE WORD HEAVY

Details from the NHTSA website.

NHTSA Campaign Number: 04V319000

Manufacturer: MITSUBISHI MOTORS NORTH AMERICA, INC.

Components: FUEL SYSTEM, GASOLINE

Potential Number of Units Affected: 44,214

Summary
ON CERTAIN SPORT UTILITY VEHICLES, WHEN THE FUEL TANK IS FULL AND THE VEHICLE IS PARKED FACING FORWARD ON AN UPWARD SLOPE, THE FUEL TANK LEVELING VALVE MAY NOT MAINTAIN PROPER SEALING IN THE EVENT THE FUEL EXPANDS FROM A RISE IN THE AMBIENT TEMPERATURE.
Remedy
DEALERS WILL REPLACE THE LEVELING VALVE. THE RECALL BEGAN ON AUGUST 30, 2004. OWNERS SHOULD CONTACT MITSUBISHI AT 1-800-222-0037 OR MITSUBISHI CARIBBEAN AT 1-787-251-8715.
Notes
MITSUBISHI RECALL NO. SR-04-008.

TSB Information:
No: SR-04-008
DATE: August, 2004
MODEL: 2002-04 Montero
SUBJECT: FUEL LEVELING VALVE AND FUEL FILLER CHECK VALVE REPLACEMENT

- SAFETY RECALL CAMPAIGN

PURPOSE
This bulletin contains information concerning a Safety Recall Campaign relating to a possible fuel leakage condition caused by the fuel leveling valve.
When the fuel tank is full and the vehicle is parked forward on an upward slope, the fuel tank leveling valve may not maintain proper sealing when fuel
expands from a rise in ambient temperature. If the fuel leveling valve does not seal properly, gasoline may leak onto the ground. Gasoline in the presence
of an ignition source may result in a fire.

AFFECTED VEHICLES
2002-04 Montero built beginning April 4, 2001 and continuing through May 21, 2004.

CUSTOMER NOTIFICATION
A letter will be sent to all owners of affected vehicles asking them to bring their vehicle to their Mitsubishi Motors dealer to have the fuel leveling valve and related fuel filler tube check valve replaced. To simplify the repair procedures, customers are being asked to bring their vehicle in with less than 1/2tank of fuel.
A copy of the customer notification letter appears later in this bulletin.

REQUIRED OPERATIONS
Before starting the PROCEDURES section of this bulletin, CHECK THE WARRANTY SUPER-SCREEN to verify that the vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.
Repair procedures will include replacing the fuel tank leveling valve and the fuel filler tube check valve according to the instructions in this bulletin.


Full Disclaimer: The repairs and information outlined in this write-up are from my personal
experience and interpretation of the TSB.
Special shoutout to @SONICMASD for sending over the TSB.


What Model Years do this affect?:
The TSB states "2002-04 Montero built beginning April 4, 2001 and continuing through May 21, 2004." However I have found out from multiple owners that it affects almost all Gen3s regardless of what the TSB states.

What exactly happens?:
The TSB states the following
"This bulletin contains information concerning a Safety Recall Campaign relating to a possible fuel leakage condition caused by the fuel leveling valve.
When the fuel tank is full and the vehicle is parked forward on an upward slope, the fuel tank leveling valve may not maintain proper sealing when fuel
expands from a rise in ambient temperature. If the fuel leveling valve does not seal properly, gasoline may leak onto the ground. Gasoline in the presence
of an ignition source may result in a fire." I have found that any steep uphill obstacle, mountain pass, or street might result in fuel spilling out as well as a very hot day with a full gas tank


Will Mitsubishi cover the repair?: Based on my communications with my local Mitsubishi Dealer AND Mitsubishi Motors NA, Mitsubishi will honor and cover the repair in the TSB ONLY if the TSB repair was not performed already. If the repair was performed back in 2004, there is only a 1 year warranty on the repair and you will not be eligible to have MMNA cover the warranty fix. (Per MMNA). Based on my research this looks like a maintenance item that should be addressed every 10 years or so. You may contact your local dealer or call/email MMNA by going here https://www.mitsubishicars.com/contact-us

How do I check if the TSB repair was performed on my vehicle or if the recall was performed? You may check to see if your vehicle is affected or if the recall was performed at the following sites. Please note I found the best way to find out was to contact Mitsubishi North America or your local dealer. The sites listed below might not accurately tell you if or if not the fix has been performed. For the most accurate answer please contact MMNA or your local dealer. You may contact your local dealer or call/email MMNA by going here https://www.mitsubishicars.com/contact-us

- https://www.mitsubishicars.com/recall#

- https://www.nhtsa.gov/recalls#vin
- https://vinrcl.safercar.gov/vin/


NOTE: I found the TSB on this to be very confusing and include a lot of information, I will be going over how I did this repair using information from the TSB. I will paste full TSB instructions on a 2nd post on this same page, if you choose to read those instead.


OEM parts required for this fix:

- Fuel Tank Leveling Valve - 1785A010
- Fuel Filler Tube Check Valve - 1755A012
NOTE: EVAP EMISSION CANISTER MIGHT HAVE TO BE REPLACED IF A LARGE AMOUNT OF FUEL HAS SOAKED THE CANISTER. Instructions will be below.

Why are we replacing both of these parts?

- The TSB states the Fuel Tank Leveling Valve must be replaced due to the original leveling valve not maintaining proper sealing when fuel expands from a rise in ambient temps.
- The Fuel Filler Tube Check Valve stops fuel from coming up from the filler neck/tube in case of accident or crash. I would assume this would also prevent fuel from rushing out of the filler tube and onto the ground.


I found what I believe to explain both parts in more detail


Fuel Tank Leveling Valve - A high flow rate fuel vapor vent valve assembly has a delayed fall away fill level control float responsive to the level of fuel in the fuel tank and constructed to control the closing of an outlet passage through which fuel vapors are vented from the fuel tank when a desired maximum fuel level is reached within the fuel tank during refueling of the tank. The fill level float is constructed to sink after refueling of the fuel tank is completed, and preferably several minutes thereafter, to control the opening of the outlet passage and permit fuel vapors to once again vent from the fuel tank. Staggered openings in the housing of the valve assembly permit the fuel vapor to vent from the fuel tank through the outlet passage when it is open but prevent splashing or sloshing fuel within the fuel tank from flowing through the outlet passage and to a vapor canister downstream of the outlet passage. During filling of the fuel tank when the outlet passage is severely restricted or closed, the pressure within the fuel tank increases to cause fuel to rise in the fill pipe and actuate the automatic shut-off of a refueling nozzle of a fuel station fuel pump and prevent substantial additional fuel from being added to the fuel tank. SOURCE

Fuel Filler Tube Check Valve - A filler neck of a fuel tank extends from the gas cap to the interior of a fuel tank, and a fill valve insert is positioned adjacent the tank-interior end of the filler neck in a tank/neck coupler construction. The insert carries a flexible valve to close the interior end of the filler neck, and the valve is designed and mounted both to flex open and bodily move downstream to both open and rapidly enlarge the valve opened passageway in response to rapid inflow of fuel to the tank, and to return and revert to a closed position upon cessation of fuel inflow. The fill valve insert is positively positioned and held in the interior of a threaded spout on the fuel tank and is retained and sealed against the filler pipe by a threaded collar screwed onto the threaded spout. In the event the filler neck is pulled loose from its frictional clamp fit in the tank/spout collar by vehicle crash forces, the tank spout will remain closed and sealed by the valve insert remaining retained by the collar in the spout to thereby prevent fuel spillage from the tank. SOURCE
 

Attachments

ChrisCosta416

Well-known member
LETTUCE BEGIN - SIMPLIFIED INSTRUCTIONS
Fuel Tank Leveling Valve

Note: I did this whole process without using an automotive lift and without dropping the fuel tank all the way
  1. Start by trying to get your fuel as low as possible, the lower the better as it will be lighter
  2. Disconnect Battery
  3. Remove rear sway bar brackets and let sway bar droop down
  4. Lower the transmission crossmember 2-4 inches down. (Great time to replace the crossmember bushings)
  5. Disconnect Filler Hose to Gas Tank ( I recommend disconnecting the upper part of the hose that goes to the metal filler neck)
  6. Remove plastic skid cover if you have one ( 3x10mm bolts in the middle and the perimeter is held by plastic trim pieces, most likely you are missing a lot if this repair was previously done)
  7. Remove 2 straps holding gas tank as wells as rear and middle perimeter nuts holding gas tank (Have a jack ready to support the tank)
  8. Lower the REAR of the gas tank supported by a jack. (Be mindful of high pressure hoses and vapor hoses
  9. Towards the rear of the tank near the rear drive shaft you will see the Fuel Leveling Valve - 1785A010 it looks like this
View attachment 643924

10. Disconnect the host connected to the Fuel Leveling Valve - Should be breather hose
11. Unbolt x5 8mm bolts on the Fuel Leveling Valve and remove Fuel Leveling Valve
12. Install new Fuel Leveling Valve in same orientation as old one (When Installing new Fuel Leveling valve ensure Rubber gasket, valve and top plate all align. Follow the indents on the leveling valve)
13. Torque x5 8mm bolts to 22+/- 4 in-lbs (INCHES)
14. Connect breather hose back.
15. Raise and bolt gas tank back up, followed by skid plate
16. Jack up and tighten transmission crossmember to it's original position at 33+/- 7 FT-LB
17. Install Swaybar
18. Connect Fuel Filler hose back to metal filler pipe (Inspect for cracks replace if needed)
19. DONE
View attachment 643927


Fuel Filler Tube Check Valve
  1. Jack up right rear of the vehicle (remove tire if necessary)
  2. Remove Filler Tube protector (Plastic trim tabs might be seized and might need to be broken off)
  3. Locate Fuel Filler Tube Check Valve (White plastic piece)
  4. Remove old and replace with new one, note orientation of valve and "Tank label"
View attachment 643925
5. Inspect lines for rust
6. Attach Filler Tube protector
7. Lower vehicle
8. DONE
View attachment 643926
 

ChrisCosta416

Well-known member
LETTUCE BEGIN - TSB Instructions


Before Starting Information
Before starting these recall procedures:
^
Check the fuel tank fuel level. If the tank is over 1/2 full, carefully drain the tank into
a clean container, until the fuel level is less than 1/2 full.
^
Remove the right side rear wheel Proceed with Sections A, B, C, & D
A. Evap. Emission Canister Insp. & Purge Procedures
The evaporative emission canister must be inspected for leakage before replacing the f
uel leveling valve and fuel filler tube check valve. If the leveling
valve leaked previously, the canister may be damaged and require replacement. Perfor
m the following checks to determine if the canister requires
replacement.
NOTE:
There should be very few cases (less than 1% of the total number of affected vehicles)
where the canister will require replacement. If you determine
that the canister requires replacement, you must call Techline for canister replacement
authorization before ordering the canister. Refer to CAPS for
the canister part number.
1.
Visually inspect the area around the canister vent pipe assembly (located at the rear of
the right rear wheel house) for any signs of fuel leakage. If
you find any indication of fuel leakage, replace the canister.
NOTE:
If canister replacement is necessary refer to Section 17 in the Service Manual. If the c
anister is replaced, purging is not required. After
replacement. go to Section 8.
2.
Start the engine and let it idle for about 10 minutes. If there is any engine stalling or se
vere rough idling, replace the canister.
3.
Connect the scan tool and check for DTCs. If DTC P0441 is recorded, replace the cani
ster.
4.
If none of the above conditions apply, do not replace the canister. Proceed with the Ca
nister Purging procedures beginning with Step 5.
Canister Purging
5.

Disconnect the purge hose and the vent hose on the right side of the canister. The cani
ster can be reached through the right rear wheel house,
above the upper suspension arm.
6.
Block off the canister vent port using a rubber damper, p/n MU72001 1 or equivalent.
Connect the hose from the Miller Pressure Pump Tool
(Miller # 6872A) to the canister purge port.
7.
Run the Miller Pressure Pump Tool for 4 complete 15 minute cycles. On the Miller To
ol, set the Pressure Hold switch to Open and the Vent
switch to Closed. The Miller Tool gauge should indicate less than 15 in. H20 during t
he purging procedure. While the Miller tool is running,
proceed to Sections B & C.
NOTE:
If the Miller Tool gauge gives a high reading (over 15 in. H20) disconnect the hose, la
beled "S" in the hose diagram, and start the Miller Tool
again. If the reading remains high, replace the canister. If the reading drops to about 1
5 in. H20 or less with the hose disconnected, a restriction
in the ORVR Vent Valve Module is indicated. Refer to Service Manual Section 13A t
o diagnose the condition.
CAUTION
During purging, if any liquid fuel leaks from the canister, stop the purging procedures
and replace the canister.
B. Fuel Leveling Valve Replacement
1.
Release the fuel pressure of the high pressure fuel line by removing the fuel pump rela
y(s) and then starting the engine and letting it idle until ii
runs out of fuel. This takes the fuel pressure off the high pressure fuel line.
2.
Remove the two bolts from each of the rear stabilizer bar bushing brackets and move t
he stabilizer bar downward.

6.
With the fuel tank supported by a transmission jack, remove the four fuel tank attach
ment nuts (two at the front of the tank and two at the rear) and
the bolt and nut from each of the two fuel tank support straps.
7.
Lower the fuel tank downward about 50 mm, then disconnect the vapor return hose, th
e vapor hose, and the purge hose at the fuel tank. Then,
disconnect the breather hose from the fuel leveling valve.
8.
Disconnect the fuel tank harness connector or move it away from the fuel leveling val
ve.
9.
Remove the five leveling valve mounting nuts, then remove the leveling valve from th
e tank. Install the new fuel leveling valve into the fuel tank.
Install and tighten the five nuts to 22 +/- 4 in-lb (2.5 +/- 0.4 Nm).
CAUTION
Be careful that the leveling valve gasket is not damaged during installation of the new
leveling valve.

10.
Connect the vapor hose, the vapor return hose. and the purge hose at the fuel tank. Then reconne
ct the breather hose to the new leveling valve.

NOTE:
Connect the purge hose before connecting the breather hose to the leveling valve.
IMPORTANT
If any of the hoses removed during this repair are damaged, replace with a new hose, referring to
CAPS for part numbers.
11.
If you disconnected the fuel tank harness connector in Step B.8, reconnect it. If you only moved t
he connector, move it back to its original
position.
12.
Reposition the fuel tank, then reinstall the four fuel tank securing nuts and the fuel tank strap atta
ching bolts and nuts. Tighten to the proper torque
value.
Torque values:
Nuts = 19 +/- 3 ft-lb (26 +/- 4 Nm)
Bolts = 16 +/- 2ft-lb (21 +/- 4 Nm

13.
Reconnect the high pressure fuel hose, the fuel return hose, and the fuel vapor hose to their respe
ctive fittings on the underside of the vehicle at the
front of the fuel tank.
14.
Move the fuel filler hose downward and insert the clip on the fuel filler hose securing zip tie into
the fuel tank cover, snapping it securely into
position.
15.
Move the transmission center member upward into its original position and tighten the mounting
bolts to 33 +/- 7 ft-lb (44 +/- 10 Nm).

16.
Move the stabilizer bar upward into its normally installed position, then install the sta
bilizer bar bushings, brackets, and bolts. Tighten the bracket
bolts to 33 +/- 7 ft-lb (44 +/- 10 Nm).
Proceed with section C. Fuel Filler Check Valve Replacement.
C. Fuel Filler Check Valve Replacement
1.
Remove the fuel lank filler tube protector.
2.
Remove the old fuel filler check valve.
3.
Install the new fuel filler check valve. Make sure the check valve is installed so that th
e arrow embossed on the check valve is pointing downward
in the direction of the fuel tank as shown.
4.
Reinstall the filler tube protector.
5.
Disconnect the Miller Tool from the canister purge port, then remove the damper used
to block the canister vent port in Step A.6. Reconnect the
canister purge hose and vent hose.
IMPORTANT:
If any of the hoses removed during this repair are damaged, replace with a new hose, r
eferring to CAPS for part numbers.

6.
Reinstall the right side rear wheel.
7.
Reinstall the fuel pump relay(s).
Proceed with section D. Fuel/Vapor Leakage Check
D. Fuel/Vapor Leakage Check
After completing the fuel leveling valve and filler tube check valve replacement, perform the foll
owing fuel/vapor leak check.
1.
If any fuel was drained from the tank, replace it.
2.
Connect the MUT-III scan tool.
3.
Start the engine and let the engine run at idle while checking for fuel leaks. If there are any leaks,
repair as necessary.
4.
Using the MUT-
III, run the Evap Leak Monitor. Then check for DTCs and provisional DTCs. If the monitor runs
successfully and no DTCs are
detected, repairs are complete. If any DTC is detected, refer to Section 13A in the service manual
to diagnose the indicated DTC.
 
Top