The Mitsubishi Pajero Owners Club®

[bomber]

I have a N reg SWB Pajero auto which in a previous thread I said that on filling up "Full" I was getting a petrol leak which went away after a few miles when the level in the tank dopped well after a good look through the Inspection hatch it now seems more likely the leak is from from the sender unit Gasket area (a bit rusty on top of tank around both sender unit and two fuel pipe plates   ) I have let a friend of mine who is a Mechanic and knows what he's doing (I certainly don't! computers yes! cars no!   )
He said he is prepared to do the job "But" the six nuts holding the sender unit onto the tank are well rusted! and he is concerned that there maybe a chance of two things happening, shearing a stud or finding "Rust Corrosion" under the Gasket on tank therefore Could anyone please point me in the right direction to obtain a Gasket for the sender unit and Fuel plate and also in the case of the worse case Scenario the "Cheapest" place to obtain a "New" fuel tank (75Ltr) Part numbers would be very much appreciated if possible, I would ask for you do do the job for me but I know that is a big ask!   Thank's


Peter

[Google]

[ahalton]

I've done a few of these, so there's no need to panic just yet, wait till I've finished and then panic  

I think there's 6 bolts holding the sender on, unless somebody has snapped the other 3 off.

You have two metal pipes coming out of the sender that connect to the flexi-pipes that go to the engine.  Where the pipes come out, they corrode and leak.

What I've done before is remove the sender, cut the metal pipes off, drill out the old pipes and replace with either copper or stainless pipe.  Use a bulkhead fitting to connect the pipes from inside the tank to the outside.

You will need to make the pipes slightly longer so that you can cut the old flexi-pipes back a bit to remove the fitting.

If you want a new tank and sender you will have to pay £600+ from Mitsubishi.

You could buy a replacement gasket from them, I just clean the old gasket, then use instant gasket.

Get copper microbore from B&Q with the fitting, cost less than a tenner, a couple hours labour.

Sorry if I've not explained it very well, its easier to do it than to explain it  

Andrew

[bomber]

[ahalton]

8mm AF head, I know because theres a Shogun driving round with my Teng spanner somewhere after I dropped it  

Take the cover off and soak them in penetrating oil a couple of days before doing it.  Squirt them a few times.  

The last one I did I used a 6 sided socket and a couple of wobble extention, only snapped one, put a bit more instant gasket on that side  

Andrew

[bomber]

thanks for all your help mate. 

Peter