1997 Montero SR Fuel Issues

[NorthLandExp]

Hello, I am new to this forum, but I just bought a 1997 Montero SR with 99,000 and have a few pressing issues which I have to tend to before getting it on the road. The most pressing issue is a pretty serious fuel leak from what seems to be a rusted out pitcock from the fuel sender. I dont believe the tank is completely gone, but have yet to thoroughly go over it. Does anyone have any experience with any similar issues or finding a replacement tank that won't break the bank?
Also it appears the brakes need a full replacement as well. They are fairly rusted, and an ABS sensor is on on the dash. The Northeast, while not taking its toll on the body or frame has certainly done a number on a few components. Essentially it has come down to whether or not i can fix this truck myself and at a price that wont make it seem like a ridiculous project. I know that I will have to do the timing belt as well pretty soon, so things are stacking up against me.
However it is a cool truck and if it can be fixed up as an expedition vehicle/ daily driver that would be awesome. Anybody have any thoughts on the fuel system/ tank replacement or guidance for threads? Also what are the thoughts on other prohibitive issues I may run across?
The biggest issue is now getting the unregistered, fuel leaking vehicle from South of Boston to Maine without having to put a ton of money into a possible junker. All good fun, sounds like a proper project truck!



Here it is passing its first hill climb with flying colors.

 

[RyanY]

You'll need to investigate further and find out what is leaking before looking for advice on replacement parts. There's an access panel under the carpet just behind the back seat that gives you access to the fuel tank sending unit - pull that out, turn the key on and see if you can tell where the leak is coming from. If you're really lucky it'll just be a simple rubber fuel line. Car-Part.com is a good resource to find used parts in your area - hopefully you'll just need the sending unit and not the entire tank. If it's the sending unit, give the pipe connections a shot with some PB Blaster or other effective penetrating oil (Not WD40! Acetone & ATF works wonderfully) as soon as possible because they're known to be a major ***** to get apart without minor destruction.

 

[Salonika]

If you diagnose a bad wheel speed sensor it will likely be a pain to remove (my diagnosis was easy, the wire was cut haha). I did one on the front. I was able to perform surgery on it with a right angle grinder and a small burr. You should be able to get it out without taking anything off other than the wheel, but it is a tight area to grind in. I carefully excavated the old one piece by piece (like a dentist ) while minimizing damage to the sleeve it fits into. Then I got a salvage knuckle with a sensor in it, which I extracted by cutting it out (around here they are almost always frozen). Cleaned it up and installed it, ABS restored. There is a jumper you can use to jog your ABS pump to see if it works. The rear sensors will probably be frozen in as well, but may be easier to work on.

Hopefully your fuel leak isn't the tank itself. Anything else shouldn't be too bad to fix, the access panel is well designed to work on the sender area.

The truck is worth saving. Have fun.

 

[BEG]

The top of the fuel tank has a depression in it where the fuel gauge sender and fuel pump sit which tends to hold water, making that whole area prone to rust. The fuel pump itself sits in a hanger that bolts to the top of the tank. The hanger has a top plate with two metal fuel lines coming out of it (supply and return) which usually rust through and cause a leak. Unfortunately, this hanger is pretty expensive from Mitsubishi (like around $600, IIRC) but there are other options. I know there's this Chinese copy available from aliexpress:

http://www.aliexpress.com/store/pro...4-Dakar-V13V-MR208665/1080127_1609174334.html

...or you can do what the DSM guys do and retrofit a -AN fitting on the hanger with something like this kit:

https://www.rtmracing.com/xcart/product.php?productid=18379&cat=1902&page=1

Be prepared for rusted fasteners and dropping the tank. You might have to drill the tank for new bolts if you snap the fuel pump mounting studs.

 

[NorthLandExp]

Ok, so finally got some time to get back to the rig. Here is a picture of the fuel tank/ fuel line issue. The line on the left that is pulling out is where it is leaking. It looks like this is an after thought line that originally came off the fuel sender as there is a plug in there. I was wondering if anyone has a picture of a stock fuel tank/ fuel sender so I can see if I just need to replace the sender and patch where the possible aftermarket fuel line is. Any thoughts anyone has would be awesome, I would love to get this thing on the road. Thanks.

 

[Salonika]

It's not an after thought line. They both hook up to something. It is a recirculating fuel system. One side is the high pressure supply, and the other is the return line. I forget right now which is which. Look under your truck in that location you should find two fuel lines to mate up to. Be careful with just using hose clamps on the high pressure side because they can blow off. Unless a previous owner got creative with the plumbing. Wait.......do I see a third fuel line in your picture? What's in the upper left corner?

 

[BEG]

Ok, so finally got some time to get back to the rig. Here is a picture of the fuel tank/ fuel line issue. The line on the left that is pulling out is where it is leaking. It looks like this is an after thought line that originally came off the fuel sender as there is a plug in there. I was wondering if anyone has a picture of a stock fuel tank/ fuel sender so I can see if I just need to replace the sender and patch where the possible aftermarket fuel line is. Any thoughts anyone has would be awesome, I would love to get this thing on the road. Thanks.


View attachment 327585

The small line with the bolt plugging the hose is the fuel return line. The other line is the high pressure feed line. It should not be hose clamped in place. Depending on the year, it should either be a traditional brass fitting or a Dorman type plastic fuel fitting. The black box with two bolts is the fuel tank pressure sensor and the white connector is the fuel pump power. The other connector that is half visible is an intermediate/ strain relief connector. The super-rusty triangular plate with three bolts and a white/blue connector is the fuel gauge sender. That other line that Salonika noticed is not supposed to be there, IIRC. This whole setup gives me the heebies.

I had similar issues with my fuel pump hanger so I modified it with -AN fitting and plumbed it all with push lock fuel hose:

 

[NorthLandExp]

Ok. Yes there is a third line at the upper left. This is the supply line from what I can see as that is where the issue is. From this post I feel like the approach is to replace the fuel sender and the tank sender (as that isnt working either) and patch the tank where the upper fuel line is? My thought is the previous owner had fuel issues at the sender and for some ungodly reason did this set up. Thoughts on patching the tank?

 

[Salonika]

I'd say the third line in the upper left is your low pressure return line. If that's your high pressure line then I have the heebies about what's going on in the tank! I would do what BEG did, he has a very nice write up on it. Then just plug that hole in the upper left with some jb weld or something and forever keep an eye on it.
What I wonder about is what is going on with the fuel lines heading to and from the engine.

 

[BEG]

Ok. Yes there is a third line at the upper left. This is the supply line from what I can see as that is where the issue is. From this post I feel like the approach is to replace the fuel sender and the tank sender (as that isnt working either) and patch the tank where the upper fuel line is? My thought is the previous owner had fuel issues at the sender and for some ungodly reason did this set up. Thoughts on patching the tank?

I don't see how that can be the supply line. There'd be no way to plumb it to the fuel pump from there. Definitely replace the stock fuel pump hanger with a good used one or modify the one you have if necessary. Here's how I did it:
http://www.expeditionportal.com/for...o-your-Mitsubishi-today?p=1974568#post1974568

For plugging the tank, I'd say go to your local autoparts store and find one of those self-tapping drain plugs in the Help! section. Add a fuel resistant seal (viton) and you should be good. I've never had any luck with fuel tank repair epoxy.

 

[All-Terrain]

Are the three studs that hold the fuel level sender in place replaceable? They are pretty well exposed to the elements...