Mitsubishi Pajero gas tank repair
The Japanese model of the Mitsubishi Pajero SUV is rightfully considered one of the most functional, used and reliable cars, having won the sympathy of millions of drivers around the world. However, the car has some standard “sores”, one of which is the frequent failure of the fuel tank. This section describes how to directly repair the Mitsubishi Pajero gas tank.
Contents of the article:
Causes of gas tank failure
As a rule, the list of the main causes of gas tank leaks on the Japanese SUV in question includes:
- Dirt on the container;
- Frequent off-road trips;
- Premature verification of technical conditions.
It should be noted that initially the developers of Mitsubishi Pajero placed the fuel tank too close to the road cleaning and equipped it with additional plastic protection; such a measure, according to the creators of the SUV, should effectively protect the steel container from mechanical damage and extend its service life. This is so.
In practice, however, everything turned out differently. Dust, dirt and salt deposits began to accumulate in the gap between the plastic body and the gas tank, causing rapid corrosion of the metal. As a result, the fuel tank will leak even on cars with a service life of no more than two to three years.
Some owners of Mitsubishi Pajeros use their SUVs to travel over rough terrain or off-road, touching the bottom of various obstacles. In this case, upgrading the car is of great benefit. Today’s tuning options can mean a lot. For example, modifications to bumpers provide a unique opportunity to protect the body and tank lancer 9 from serious damage. Elements are reinforced using various technologies.
In critical cases, plastic protection not only saves the gas tank from deformation, but also hides traces of serious impacts. As a result, microcracks form and fuel begins to penetrate in small quantities. Car owners may not notice such a malfunction until the leak becomes global.
After 5-6 years of operation of Mitsubishi cars in Japan, experts recommend checking the technical condition of the fuel tank at least once a year.
This should include:
- Drive the car into the room;
- Remove protection;
- Evaluate the appearance of the tank.
If you notice signs of serious deformation, cracks or corrosion, it is best to quickly replace the item.
All known modifications of fuel tanks
Additional information.
It is recommended to remove the left rear wheel when the car drives into a hole. This will allow you to additionally reach all hard-to-reach fasteners and speed up the process of dismantling the gas tank. NOTES. If all operations to replace the fuel tank are planned to be carried out on a lift, the wheel does not need to be removed, as it does not interfere.
| After removing the plastic protection, drain hose clamps are installed and the sea neck hoses are loosened one by one. Follow the same procedure for the fuel control and fuel return hoses. Don’t forget to disconnect the high pressure hose from the fuel filter. | At the last stage, the electrical contacts on the fuel pump connector are disconnected and the current fuel level is determined. The first function is located at the top of the tank, the second is on the right side of the tank (passenger side of the car). After making sure that all the listed measurements are performed correctly, proceed to the main part of the exchange. | The fuel capacity of a Mitsubishi Pajero car is done by unscrewing four nuts. This allows the containers to be mounted directly on brackets on the car frame. | |
| Very often these elements are subject to corrosion, so they are pre-moistened with a composition such as WD40. This allows you to remove all fasteners in the future without unnecessary effort. | Then the tank is carefully removed, after which its technical condition is checked. | The fuel capacity of a Mitsubishi Pajero car is done by unscrewing four nuts. This allows the containers to be mounted directly on brackets on the car frame. | When replacing an old gas tank with a new analogue, all the described steps are performed in the reverse order, but all clamps must be fully tightened to further eliminate the possibility of leaks during the installation process. |
| Adviсe. It is also recommended to flush the tank before installing any fluid containing alcohol (solvent 646 is suitable). | If you decide to save your own money and repair your fuel tank, it won’t hurt to listen to the useful advice of an expert. | The fuel capacity of a Mitsubishi Pajero car is done by unscrewing four nuts. This allows the containers to be mounted directly on brackets on the car frame. | It’s a good idea to replace the fuel pump unit gasket, followed by the fuel level sensor. |
To remove the above-mentioned components, first treat any nuts that have become stuck to the mounting studs with WD40, possibly due to vehicle operation. Then, remove the old gasket, install a suitable replacement, and tighten the retaining nut to ensure a tight seal on the gas tank.
Preparing to remove the gas tank
Before removing the fuel tank, several preparatory steps must be completed, including:
- Drain the fuel.
- Remove the rear left wheel.
- Remove the protective cover.
- Disconnect the feed hose.
- Disconnect the fuel pump connector and sensor contacts.
It is very difficult to effectively replace even a half-full fuel tank. Therefore, immediately before removing the gas tank, drain any fuel that is practically empty or highly flammable into a prepared container. In the first case, after the warning light appears on the dashboard (the so-called lako icon, tano-soling), you can drive about 50-70 km. After this, up to a few liters of fuel remain in the tank.
However, experienced repairmen do not recommend this. This is not recommended because sediment often accumulates at the bottom of the gas tank, which can quickly clog the fuel filter. This is also stated in the instructions. It is best to carefully unscrew the 12 drain bolts at the bottom of the tank and drain all the gasoline (or diesel fuel).
It is recommended to remove the left rear wheel when driving the vehicle into the pit. This will allow additional access to all hard-to-reach fasteners and speed up the process of removing the gas tank.
NOTE: If all fuel tank replacement operations are planned to be performed on a lift, the wheel can be left in place, as it will not interfere. After removing the plastic cover, install the drain hose clamps and loosen the fuel filler neck hoses one by one. Follow the same procedure for the fuel pressure control and fuel return hoses. Don’t forget to disconnect the high-pressure hose from the fuel filter.
After removing the plastic protection, drain hose clamps are installed and the sea neck hoses are loosened one by one. Follow the same procedure for the fuel control and fuel return hoses. Don’t forget to disconnect the high pressure hose from the fuel filter.
Removing and Repairing the Fuel Tank
Removing and repairing the gas tank
These components are often susceptible to corrosion, so they are first moistened with a solution such as WD40. This allows all fasteners to be removed without unnecessary effort.
Very often these elements are subject to corrosion, so they are pre-moistened with a composition such as WD40. This allows you to remove all fasteners in the future without unnecessary effort.
When replacing the old gas tank with a new one, follow all the steps described in reverse order, but during installation, be sure to tighten all clamps thoroughly to prevent future leaks.
Tips: It is also recommended to flush the tank with an alcohol-based solution (646 solvent is sufficient) before installation to significantly extend the life of the fuel filter.
If you’ve decided to save money and repair your fuel tank, there’s nothing wrong with heeding some helpful advice from an expert.
When repairing a Mitsubishi Pajero’s gas tank (painting, repairing cracks, removing dents), it’s necessary to replace the filler neck gasket, which is where fuel passes when filling the tank.
- It’s also a good idea to replace the gasket on the fuel pump block, above which the additional fuel level sensor is mounted. This can often fail for various reasons.
- To remove the above-mentioned components, pre-treat any nuts that have become stuck to the mounting studs, possibly during vehicle operation, with WD40. Then, remove the old gasket, install a suitable replacement, and tighten the retaining nut to ensure a tight seal on the gas tank.
Repairing Cracks and Painting
Repairing cracks and painting
Gas cylinders can only be painted after removing the old coating. Fine-grit sandpaper is ideal for this. If corrosion is discovered on the container during paint removal, these areas should be treated with a rust converter, which will slow down the deterioration of the metal.
Adviсe. Acrylic enamels are the best choice for painting. Acrylic enamels have excellent resistance to aggressive acid-base environments. Before installation, the fuel tank should be dried and checked for leaks.
Therefore, repairing a Mitsubishi Pajero gas tank is an extremely important undertaking that requires a thoughtful approach, appropriate knowledge, skills and the availability of suitable equipment. The price of a Pajero fuel tank is approximately 50, 000 rubles.
Mitsubishi Pajero gas tank repair
