Fuel Pump

REMOVAL & INSTALLATION

Montero

NOTE: The manufacturer recommends draining of the fuel tank.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative battery cable

   CAUTION
   The fuel injection system remains under pressure after the engine has been

   OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

4. Rear floor carpeting

   Fig. 1: The fuel pump on the Montero is removed through the rear floor pan

5. Fuel pump cover
6. Fuel pump connector and the fuel hoses
7. Fuel pump assembly

   To install:

8. Install or connect the following:
   • Fuel pump assembly into the fuel tank. Torque the nuts to 24 inch lbs. (2.5 Nm).
   • Fuel lines and the fuel pump connector.
   • Fuel pump cover. Torque the bolts to 108 inch lbs. (12 Nm).
   • Rear floor carpeting.
   • Negative battery cable
9. Refill the fuel tank, if drained
10. Start the vehicle; check for leaks and proper operation.

Montero Sport

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Properly relieve the fuel system pressure.
3. Remove the fuel tank drain plug and drain the fuel from the tank.

   CAUTION
   The fuel injection system remains under pressure after the engine has been

   OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

4. Remove or disconnect the following:
   • Negative battery cable

   CAUTION
   Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

5. Fuel tank protector, if equipped
6. Fuel tank from the vehicle
7. Fuel pump retaining screws and the pump from the tank

   To install:

8. Clean the seal area of the tank.
9. Install or connect the following:
   • New gasket
   • Fuel pump in the same position as originally installed.
   • Fuel pump retaining screws, Torque the nuts to 22 inch lbs. (2.5 Nm).
   • Fuel tank. Torque the bolts to 20 ft. lbs. (27 Nm).
   • Fuel tank drain plug and the fuel tank protector, if equipped
   • Negative battery cable
10. Refill the fuel tank and install the cap.
11. Check fuel system for leaks.