Sylvie Willis
The Mitsubishi Pajero is a popular car model, especially in Australia, due to its size, diesel engines, and off-road capability. However, one common issue that Pajero owners face is the small fuel tank, which can be inconvenient for long-distance travel. To address this, some owners have opted to install long-range fuel tanks or auxiliary tanks to increase the vehicle's range between fill-ups. While some choose to install auxiliary tanks, others have shared their experiences with DIY fuel tank modifications, which involve custom-made aluminium or steel tanks installed in the rear seat well. Additionally, some Pajero owners have encountered issues with contaminated fuel or mistakenly adding petrol to their diesel engines, requiring them to drain the fuel tank or replace the fuel filter.
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What You'll Learn
Removing the rear seat cushion
To open the fuel tank of a Pajero, you must first remove the rear seat cushion. Here is a detailed, step-by-step guide on how to do this:
Start by locating the rear seat cushion in your Pajero. It is usually held down by two clips at the front edge. Gently pull up on the front edge of the seat cushion to release it from the clips. Be careful not to pull too forcefully, as you don't want to damage the clips or the seat cushion.
Once the front edge is released, move to the back of the seat cushion. There should be a lever or a latch mechanism that releases the seatback. If there is a lever, simply pull or push it to release the seatback. If there is a latch mechanism, you may need to lift a small flap or cover to access it, then pull or push the latch to release. With the seatback released, carefully lower the seatback down towards the rear of the vehicle, resting it against the backrest of the rear seats.
Now that the rear seat cushion is accessible, you will need to disconnect any wiring harnesses or retention cables that may be attached to it. These could be for features such as seat heaters or power adjustments. Make sure to disconnect them carefully and set them aside, ensuring they don't get tangled or damaged.
At this point, you should be able to remove the rear seat cushion. Gently lift and pull it towards you, sliding it out from under the seat track or rails. If it seems stuck, check for any obstructions or additional retention mechanisms. There may be clips, hooks, or other fasteners that need to be released before the cushion can be completely removed.
Once the rear seat cushion is removed, place it aside in a safe location, preferably somewhere clean and dry, to avoid damaging the cushion or its covering. Now you should have access to the fuel tank and can proceed with the next steps of your maintenance or repair work. Remember to re-install the rear seat cushion properly and securely before using your Pajero again.
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Disconnecting the positive terminal of the battery
Step 1: Park your Pajero on a level surface and engage the parking brake. It is important to ensure that the vehicle is secure and will not move during the process.
Step 2: Locate the battery. The battery in a Pajero is typically located in the engine compartment, usually towards the back on the passenger side. It is a rectangular unit with two terminals, one positive (+) and one negative (-).
Step 3: Identify the positive terminal. It is typically marked with a red cover or a "+" sign. It is important to be certain that you are disconnecting the correct terminal.
Step 4: Gather the necessary tools. You will need a suitable socket wrench or a wrench that fits the battery terminal clamp. You may also want to wear protective gear, such as gloves and eye protection, to avoid any potential hazards.
Step 5: Loosen the clamp bolt. Use the wrench to loosen the clamp that secures the positive battery cable to the terminal. Turn the bolt counterclockwise to loosen it, but do not remove it completely yet.
Step 6: Detach the cable. Once the bolt is loosened, you can carefully remove the cable from the terminal. Be gentle and avoid pulling on the cable itself, as this could cause damage.
Step 7: Isolate the terminal. After removing the cable, place the disconnected end away from the battery, ensuring it does not touch any metal surfaces or create a spark. You may want to secure it with tape or a cable tie to prevent accidental contact.
Step 8: Verify the disconnection. Check that the positive terminal is no longer connected to the battery by gently pulling on the cable. Ensure there is no resistance or tension, indicating a complete disconnection.
Step 9: Secure the work area. Once you have confirmed the disconnection, you can tighten the terminal clamp back into place to ensure it remains secure and does not accidentally make contact.
Step 10: Mark the disconnected battery. To remind yourself and others that the battery is disconnected, you may want to attach a label or hang a tag on or near the battery. This will help prevent anyone from accidentally reconnecting it during the fuel tank work.
Remember, working with batteries and fuel systems can be dangerous, so it is essential to follow safety protocols and consult a professional if you have any doubts or concerns.
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Unscrewing the screws holding the square cover
To open the fuel tank of a Pajero, you need to first disconnect the positive terminal of the battery. Next, remove the rear seat cushion by pulling up the front edge gently. The rear seat cushion is held down by two clips that can be removed by yanking them free. Once the cushion is removed, you will have access to the square cover closest to the fuel filler side that is held down by four screws. Use a screwdriver to unscrew these four screws in an anti-clockwise direction. Be sure to keep the screws in a safe place so that you can easily screw them back in when needed.
Now that the screws have been removed, you can lift the square cover away to expose the tank access port. Before proceeding any further, it is important to dust off the tank access port thoroughly to remove any dirt or debris that may have accumulated. Only then should you proceed to disconnect the gauge plug and the high-pressure and low-pressure fuel hoses. These hoses can be neatly tucked away under the floor to keep them out of the way.
With the square cover removed, you will now have access to the fuel tank and can proceed with any necessary maintenance or repairs. It is important to exercise caution when working with a vehicle's fuel system and to ensure that you are working in a well-ventilated area to avoid inhaling fumes. Always refer to the vehicle's manual or seek professional assistance if you are unsure about any aspect of the process.
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Removing the hose clamps
To remove the hose clamps, start by locating the syphon breather hose. This is a pipe about 0.5 cm in diameter. Remove the hose clamp and pull the hose off. Next, locate the 2mm diameter rubber hose that joins a metal T-section part at the back of the fuel tank. Take off the hose clamp and pull the hose off.
Now, go to the very front of the fuel tank. Here, you will find two 3 to 4mm hoses going onto two metal pipes of the fuel tank. Remove the hose clamps and pull the hoses off. Ensure you are working by feel and referring to the Russian online manual diagrams to identify the parts accurately.
Once all the hose clamps have been removed and the hoses disconnected, you can proceed to lower your jack and take out the fuel tank. It is important to note that these instructions are based on a forum post for a diesel NT Pajero, and your specific model may vary. Always refer to the appropriate manual or seek professional advice if you are unsure about any steps.
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Disconnecting the fuel lines
Locate the Fuel Lines: Begin by identifying the fuel lines that need to be disconnected. This may include both high-pressure and low-pressure fuel hoses, depending on the specific task at hand.
Prepare the Work Area: Before proceeding, it is essential to take necessary safety precautions. Wear protective gear, such as gloves and eye protection, to safeguard against any fuel spills or spray. Ensure the work area is well-ventilated to prevent the buildup of flammable fumes.
Relieve Fuel Pressure: Before disconnecting any fuel lines, it is crucial to relieve the fuel system pressure. Consult your Pajero's repair manual or seek guidance from a professional mechanic to ensure this step is performed correctly for your specific model.
Disconnect the Fuel Lines: Once the pressure is relieved, you can proceed to disconnect the fuel lines. Using the appropriate tools, carefully loosen or remove the clamps or fittings securing the fuel lines in place. Depending on your Pajero's configuration, you may need to disconnect the lines at both the fuel tank and the engine. Take note of the routing and orientation of the fuel lines to facilitate proper reconnection.
Capture Spilled Fuel: As you disconnect the lines, be prepared to capture any spilled fuel with a suitable container. Have absorbent pads or rags ready to wipe up any fuel that escapes during the process.
Secure the Fuel Lines: After disconnecting the lines, securely fasten or cap the ends to prevent any leakage and avoid introducing contaminants into the fuel system. Ensure that the work area is clean and free of any fuel residue.
It is important to approach this task with caution and a thorough understanding of your Pajero's fuel system. Always refer to reliable sources or seek advice from qualified mechanics if you have any doubts about the procedure.
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Frequently asked questions
Here are the steps to open your Pajero's fuel tank:
- Disconnect the positive terminal of the battery.
- Remove the rear seat cushion by gently pulling up on the front edge; it is held down by two clips.
- Unscrew the four screws holding down the square cover closest to the fuel filler side.
- Dust off the tank access port and disconnect the gauge plug and the high-pressure and low-pressure fuel hoses.
Ensure you are working in a well-ventilated area and avoid any open flames or sparks.
If your Pajero is struggling to start or you notice a decrease in fuel efficiency, it may be time to replace the fuel filter. It is recommended to replace the filter every 60,000 km or when you replace the timing belt.
You can use a Ryco Z658 filter, which is suitable for all MPI models (2.0, 1.8, 1.6).
The cost of the fuel filter itself can vary, but a Ryco Z658 can be purchased for around $70. The labour cost for replacement can vary depending on your mechanic, but you may be quoted around $450 for the job.
