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
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