Pajero 4x4
Living With A Mitsubishi Pajero
Pajero Fuel Filter Change
This is one part of the servicing I’ve been putting off for a while. It just looked a little complicated to me and when you start playing about with fuel lines and things it worries a relative newbie with the spanners. Anyway, it had to be done and I was determined to do it myself, so here’s the write-up with some pictures.
As usual with the Pajero there are several theories on how often the fuel filter should be replaced. These include: Every 12 months, every 40000 miles, only when you think it might be causing a problem. At this point for me I don’t when the fuel filter was last changed (if ever) so I need to do it now for peace of mind. Then I can decide how often to do it in the future at a later point.
The first thing you have to do when performing a Pajero fuel filter change is to find the bloody thing! Here’s a photo of where the fuel filter is located on my 2.8 before I remove anything:
As will become obvious in this write-up you need much more access than is available at this point. You at least have to take off the intercooler (big silver/black thing to left) and those who have two batteries as I do often talk about removing the battery nearest to the filter as well. I managed just fine with only removing the intercooler. If you don’t know how to do this, have a look here first: Removing the Pajero Intercooler
Once the intercooler is out of the way we can see a much better view of the fuel filter which is arrowed below.
Right, now we can see the thing we need to remove the 2 fuel pipes. These are pretty obvious to see, coming off the front of the fuel filter unit. In theory you can do this with a screwdriver but I found it easier with a socket. Once removed there will be a little diesel leakage from the pipes but not much when I did mine. Note: you might wish to label these pipes before you remove them so you know which goes where when refitting.
Now it gets fiddly. Have a look down the back of the fuel filter housing and you should see the 2 bolts that hold it all in place. A socket extension was called for here – remove the 2 bolts.
Pull the whole fuel filter unit away from the bulkhead carefully and you’ll see that it is attached to 2 electrical clips. Undo these and try not to get diesel into them as I’m reliably informed this can damage the seals inside. You should now be able to take the whole fuel filter unit away from the vehicle, watching out for the diesel spilling out.
Ideally you have a vice available at this point. Otherwise you’ll have to improvise. Keep the unit upright and place the plastic water sensor (right at the bottom) very gently in the grips of the vice – just enough to get a hold of it (see photo below). Twist the filter and housing anti-clockwise to loosen, but not remove the plastic water sensor.
Now open up the jaws of the vice and grip it tightly around the body of the fuel filter itself (not the top housing). Twist the top housing anti-clockwise to remove the fuel filter. Drain any diesel from the fuel filter now. Then unscrew the plastic water sensor all the way out so it’s removed.
Here’s a photo of the whole thing taken apart. Left to right: New Mitsubishi fuel filter, old fuel filter, fuel filter housing. Bottom: Water sensor. Also notice on the water sensor the arrowed o-ring. In the box of the Mitsubishi fuel filter that I bought there was a new o-ring to go here which I obviously replaced. Not sure if this is the case on an after market fuel filter?
Let’s put it all back together!
Put the new o-ring onto the water sensor and then screw this into the new fuel filter. I couldn’t find out how tight this is supposed to be really, so I did it as tight as I could with my fingers and then gave it a final nip in the vice.
Now open up the vice and hold the fuel filter itself in place and screw on the filter housing. Again there’s no real test of how tight, it’s a guess really.
Right, now we’re ready to go back to the truck with it. Hold the unit roughly where it’s going to sit and put back the two cable clips you removed before taking it out. Then put back the 2 bolts at the back and tighten them up.
Now we need to put the fuel pipes back onto the front of the housing. Mine had these old clip things that I tried tightening but after a certain point they just seemed to spin. I really wasn’t confident about them so I replaced them with some small jubilee clips. My local motor factors had them labelled up specifically as fuel line clips.
At this point we’re almost done, but the fuel filter needs ‘bleeding’ to pull through the diesel and and fill the unit with fuel, therefore removing any air. The manual I followed showed a fuel filter housing with a different pump and air plug arrangement to mine, so I can only describe how mine looks and works. Yours might be different, but the principle’s the same.
I’ve shown a close up of the top of my filter housing below to show the relevant parts. Unscrew the white disc on the left which is the pump. Now undo the bleed screw (a few turns) which is the big nut in the centre. Work the pump until until fuel without bubbles comes out of the bleed screw. Now tighten the bleed screw and pump again until resistance is felt. Now tighten up the pumping disc.
Have a final check to make sure everything you took off is back in place securely, then put the intercooler back on. Now fire her up and off you go.
All in all a job that I needn’t have been worried about at all that could be done from start to finish in about half an hour with a little experience.
I’d love feedback on this post. What do you think about what I’ve written? Any tips on how to do it better/more efficiently. Anything you think I’m doing wrong? Please let me know in the comments box below.
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September 24th, 2007 at 11:40 am
this information is priceless, ive just bought a pajero and like yourself dont know when the fuel filter was last changed, so rather than pay a garage to do this simple task, im going to do it myself, so thankyou very much for sharing this information with us other owners.
December 28th, 2010 at 7:38 pm
just done my fuel fillter on 2.5 lwb the way that u said took about 1 hour now i know how to do next time 1/2 thanks fillter cost £10
September 24th, 2007 at 11:49 am
Hi Tam – thanks for your comment and kind words. Makes it all worth while. Good luck with your new Pajero.
Tim
September 30th, 2007 at 2:16 am
Thanks for that, I too have just bought a Pajero and unfortunatly it wouldn’t pull the skin of the preverbial rice pudding, I have put this down to fuel starvation, therefore the filter is the first thing to go, hopefully that will do the trick, also I have a poor cold start problem, I’ll try new glow plugs and modify the buss bar ie make a new one, if that doesn’t do the trick I’ll wire in a pre heat button, save any mucking around, all this will have to wait until I get back from offshore off course, can’t wait to get back to it.
September 30th, 2007 at 8:08 am
Hi John – thanks for the comment.
It’ll be interesting to know if a new filter does the trick. Must be pretty dirty if it does. Perhaps check the fuel lines as well for muck?
I’d also be interested to hear how you get on with the glow plugs/cold start situation. As the cold weather approaches mine’s getting a little harder to start in the morning so I might need to look into this.
Tim
October 6th, 2007 at 7:58 am
Just an update on the fuel filter change, You should have seen the sludge that was in the filter, dirty brown sludge, it’s a wonder it was going at all, little wonder it was guttless, it’s gone from a maximum speed of 60mph with your foot to the boards to 85mph with ease, I realise the’re not built for speed but one must be able to overtake safely, so again thanks for your tips on removing the filter.
As for the poor starting, while I had the intercooler out of the way I took advantage of the free work space and removed the buss bar and glow plugs, the bar was perfect, not so for the plugs though, they were totaly burned out, not a very well maintaned vehicle at all.
A few niggley things to sort out now, My insurance company will not cover me for theft until I fit an immoboliser, any suggestions on a fairly easy one to fit anyone?
also the lights on the consul for the driving wheels indicator are not all illuminating, does anyone know if this is a sensor fault or simply bulbs?
October 6th, 2007 at 1:47 pm
Hi John, thanks for the interesting update.
Bet you’re glad that you changed the filter then! Just shows what a little servicing can do. Must say mine was pretty clean when I removed it, but the rest of the car’s in great condition too. Obviously new glow plugs were badly needed too.
Yeah, my truck had an immobiliser on when I bought it, so I was lucky. I’ve heard there are good alarm/immobilisers to be had on ebay for about £80 – self fit.
The lights for the wheels are a very common problem. Should be just replacement bulbs needed. One of mine doesn’t work so I’ll be sorting it soon and will write a post about it. I hear it’s an easy job.
Tim
October 26th, 2007 at 5:13 pm
Thanks this made the whole thing effotless
October 26th, 2007 at 5:56 pm
Hi Jay – glad it helped.
December 6th, 2007 at 5:45 pm
Thanks for the information you provided. It has been very helpful and provided me with the confidence to undertake a task I would not normaly risk, especially in a field in the middle of Spain !!!!!!!!!
December 6th, 2007 at 7:00 pm
Great stuff Andy, hope it works out OK for you. Hope the weather’s better there than it is here right now.
December 7th, 2007 at 7:48 pm
Thanks for this – it’s just the sort of site I need. I need to do an oil and fuel filter change tomorrow, so I’ll be following your lead.
December 7th, 2007 at 10:42 pm
Thanks for that Pete – hope it goes well for you (piece of cake!). I’m going to have to do a write up of an oil change next time I do one as well.
January 21st, 2008 at 5:39 pm
Good photos and writing. A tip worth noting, before bleeding the fuel filter, fill it with clean diesel, less pumping after refit so remove air. A worthwhile investment is a filer wrench, I like the nylon strap kind as I use it for tightening and untightening other things that I don´t want to leave marks on. I was also told by a mechanic friend of mine that when he changes fuel filters and they were very dirty, he actually fills the fuel filter with an injector cleaner (Wynns or Wurth I think) to clean the injectors and lines, the engine smokes for a short while, but a run at operating temp soon clears this and reduces emissions for the all important MOT test. As for how tight, hand tight + about half a turn but not too tight. All in all a great site.
January 21st, 2008 at 7:03 pm
Hi Adam – thanks for posting.
Excellent tips, especially filling up the filter before refitting – I’ll be doing that next time. Also interesting to hear about your mechanic mate’s tip for injector cleaner. Luckily for me every filter I remove on this Paj seems to be well clean, but I’ll bear it in mind in the future.
Glad you like the site – lots more work to do on it yet.
Tim
February 28th, 2008 at 4:38 pm
I found on my pajero, 2.8 D . If you remove the battery it saves a lot of time removing the intercooler. Please can someone tell me if there is a second filter around the fuel tank i am having problems with mine pajero. Thank you. pete london
February 28th, 2008 at 6:32 pm
Hi Pete. Yes there is another filter on the pick up pipe in the tank. Not sure how you get to it though as I’ve never done it.
November 22nd, 2008 at 10:14 pm
Thanks…great help for me…my pajero is just like yours and the pictures are wonderful…really appreciate your efforts to share with the rest of us – like you say – took me ages to find the thing – and its evident no-one has changed it
November 22nd, 2008 at 10:58 pm
Hi Ingrid.
Many thanks for your kind comments. They kind of make this site worthwhile to me!
Tim
April 3rd, 2009 at 1:07 pm
We have had a 1996 2.8 in the family for ten years.
Since the death of my brother it now resides with me in France.
Very encouraging to find the enthusiasm shown by all the correspondants. I certainlly appreciate the helpfull hints and expertise sharing.
I suspect like most newcomers we only hook up when we have a problem to share.
My propblem not reading ###enese very well concerns a warning light between the handbrake and seat belt indications. This light has an ABS and circles imprime and was first noted when the autospeed control wouldn’t engage. It now comes on after driving for a few miles/kilometres and stays on until a delay and the next restart.
Can anyone help as assistance from Mitsubishi is difficult in France.
Thank you to all once again for such an an interesting site and hope that I can contribute in future rather than just pose a problem.
Stingray
April 28th, 2009 at 8:17 pm
Thanks for all the photos and information, changed the filter without any problems.The filter on my 2.8 had a pump on top which needed to be pressed quite a few times to fill it full of diesel and then started first time.
I found it easier to remove both the intercooler and battery for maximum access as this was the first time i have changed a fuel filter, come to think about it this is the first diesel i have owned. Many thanks
April 29th, 2009 at 7:03 am
Hi Andy. Glad this helped.
May 1st, 2009 at 4:26 pm
I like what you have done mate looks good…
Keep it up shows a lot of people how to do it with out pay someone a lot of money to do it for you, and it around a £5.00 for a filter it is a cheap way as well.
When we do our we just take the battery out next to it and use a oil filter removal tool save taking it all out…
keep it up
thanks
john
May 1st, 2009 at 4:39 pm
If people want to change the filter in the tank it is not hard at all.
Fold the back seat up and lift the carpet up and you will see a plate with some 12 mm bolts. Undo them and lift the plate.
You will see the 10mm bolt in the top of the tank undo them then remove the two pipes but make sure you do not put them back on the wrong way.
now the hard bit lift the plate up but don’t break the rubber seal. As you will need a new one if you do. as you lift the plate off you will see the little filter on the end of the pipe, replace it or just clean it with washing up or any other cleaner (wash out all cleaners and let it dry right through) then put back on. then put it all back together.
30 min max.
thanks
john
May 1st, 2009 at 5:47 pm
Cheers John, I’m sure that will help a few people out there. I might just try that tank filter change myself now!
May 13th, 2009 at 1:41 pm
Fantastic post, as a complete newbie to pajero managed to change filter with no real problems, had no vice so took bit time. Appreciate post.
May 13th, 2009 at 1:59 pm
Glad it helped you James and thanks for the feedback
May 26th, 2009 at 9:31 pm
Good Man !!
I put my old girl in for servicing recently and i am sure the fuel filter aint been changed, now I can do it myself !!
Cheers kiddo.
Graham
May 27th, 2009 at 6:59 am
Go for it Graham, could make a big difference to the running of your car if it’s not been done for a while.
May 30th, 2009 at 6:02 pm
Excellent advice. I changed the filter prior to seeing this advice and I didn’t bleed the filter. it runs alright. Should I replace the filter as I am told it could be damaged. Could the pump be damaged now. Regards
Richard
May 30th, 2009 at 6:46 pm
Hi Richard.
Not sure how the filter could be damaged from not bleeding it, but I’m no expert! Don’t know about the pump being damaged either, so I’m not much help really am I? I’d ask on one of the Pajero forums for some more educated advice. I’d be interested to know if you find out.
July 19th, 2009 at 12:43 pm
Done mine yesterday, exellent write up Tim, by taking it off it gives you a chance to clean and check the whole thing, Nice one mate, Never done a deisel before, was a bit worried about bleeding the system, But not anymore! regards Derek
July 19th, 2009 at 1:23 pm
Glad it helped Derek. Doing mine again next week, weather permitting.
July 31st, 2009 at 3:12 pm
hi i have the 2.5 exceed that has run out can that little pump on the fuel filter bring the fuel back or can turning the engine bring the fuel back to filter or do you think takeing the it off and re filling it will do can you let me no thank aaron
September 12th, 2009 at 5:26 pm
cheers tim just done fuel filter on my very loved pajero 2.8td great advice ..now runs like new again,,,thanks…robbie
September 12th, 2009 at 5:32 pm
after doin filter change..my loved pajero runs great again..loads of power…respect tim..fantastic easy to follow instructions..will do mine regular now.cheers again,,tim..
September 22nd, 2009 at 6:13 pm
Hi what a Gent you are Fuel /Oil /Air Filtres Oil Change Rad Flushed ALL DONE in a DAY!! Many Thanks for YOUR HELP! Sit down and have a nice cuppa Cheers Tim
September 22nd, 2009 at 6:46 pm
Well done Gary!
September 24th, 2009 at 1:39 am
excuse my ignorance, but how exactly do you ‘work’ the pump?
September 24th, 2009 at 6:55 am
Hi Zoe
Simply push it in and out.
September 27th, 2009 at 11:41 am
oh great, thanks. i wasn’t sure if i needed to start up the car or what. i’m pretty new to all this. great post.
cheers
September 29th, 2009 at 8:50 pm
could you tell me if the pump that forces the air out should have a small o ring in it please????
September 29th, 2009 at 9:02 pm
Can’t remember Sean as it’s been a while since I’ve done it. Try asking here: http://www.pocuk.com/forums/
September 29th, 2009 at 9:18 pm
ok cheers mate
October 12th, 2009 at 6:23 pm
problem de recodement d’inter cooler entré et sorti merci.
October 12th, 2009 at 6:34 pm
Je ne parle pas Français – je Suis Désolé.
November 19th, 2009 at 10:29 pm
Well Done Tim, Great piece of work ! I have a question if anyone can help ?
My fuel filter was clogged and causing low power when under load. Changed the fuel filter (engine side) and air filter and also put in the injector cleaner. Now it runs like a dream apart from starting ! Before I did the work there wasn’t a problem starting now it’s very lumpy and kicks out a lot of black smoke. The exhaust pipe is really sooty too when 1st started. The glow worms were changed about 10 months ago
Thanks in advance for any help
Adam
November 20th, 2009 at 8:09 am
Hi Adam
I suppose based on you having a clogged fuel system and the fact you’ve just changed the filter, there might still be a problem with the fuel system. Maybe changing the filter shifted the problem if you know what I mean.
I’d have a check over the fuel filter first and make sure it’s not got any air in and then check the rest of the fuel system. You know there’s also a filter in the fuel tank?
Just a process of elimination I guess. Good luck with it.
November 24th, 2009 at 9:57 pm
Thanks Tim
Yes I located the filter in the back of the Truck under the seats but can’t get the screws out. Think this is a good indication it’s never been touched ! I’ll give it a proper go at the weekend. Tested my glow plugs and had one that had shorted out so replaced. It’s a little better but not great. I have a hunch that the o’ring on the filter could be dodgy or could have been fitted incorrectly. Getting it checked out again tomorrow
I’ll keep you posted.
AB
November 24th, 2009 at 10:07 pm
Hi Adam
Interesting about the glow plug as it had new ones not long ago. Hmmmm…..
Good luck with the tank filter, probably worth doing anyway. Did you get a new O ring with your new filter? I know the Mitsubishi ones come with a new one. Sounds feasible that it’s not on right, easy to over or under tighten.
Let us know how you get on.
November 27th, 2009 at 5:08 pm
i have had my pajero for a year now, and i’ve had it serviced 3 times this year. my car runs really well for about a month but after that when i start it up it stalls a couple of times and feels like it loses power until it warms up. i’ve narrowed it down to a fuel problem, maybe the fuel filter. is this a common problem? and do you know what i can do about it? instead of changing the fuel filter once a month.
lee