The fuel system on the Mitsubishi Pajero EXE includes a fuel filter that is responsible for keeping the diesel clean. The diesel flows into the fuel filter from the fuel tank. Once the diesel enters into the fuel filter, it flows through the fibered filter inside of the fuel filter housing. The fibered filter then catches and holds any impurities from the diesel. Mitsubishi recommends changing the fuel filter on the Pajero EXE every 40,000 miles.
Park the Mitsubishi Pajero EXE in a ventilated area. Pull the bonnet latch and raise the bonnet.
Walk to the rear of the Pajero and remove the gas cap. This will take the pressure of the fuel lines and the fuel filter.
Remove the intercooler from the top of the engine. The fuel filter is below the intercooler. The intercooler looks like a radiator that is lying flat on top of the engine. Remove the bolts from both sides of the intercooler with the 3/8-inch drive ratchet and a socket. Then, remove the electrical plugs and lines from the back of the intercooler. Pull the intercooler out of the engine area and set it on the ground.
Locate the fuel filter below the intercooler area. The fuel filter has two fuel lines that are connected to its front. Position the dripping pan underneath the Pajero in the general area of the fuel filter.
Remove both of the fuel lines with a Phillips-head screwdriver. Turn the clamp bolts counterclockwise to loosen the clamps. Twist and pull on the fuel lines at the same time until the fuel lines come off the fuel filter pipes.
Remove the two fuel filter bracket bolts from the back of the fuel filter with the 3/8-inch drive ratchet, extension and a socket.
Unplug the wiring harness from the back of the fuel filter. Then, pull the complete fuel filter housing out of the engine bay and set it on the ground.
Position the jaws of the large channel-lock pliers around the bottom portion of the fuel filter. Hold the bottom portion of the fuel filter just tight enough so that it does not turn.
Turn the top portion of the fuel filter housing counterclockwise until it loosens from the bottom portion of the fuel filter. Finish unscrewing the top of the fuel filter and set it on the ground.
Remove the round, white water sensor from the bottom of the fuel filter with the channel-lock pliers. Remove the O-ring from the water sensor and replace it with the new O-ring that comes with the new fuel filter.
Fill the new fuel filter canister up with diesel. Then, twist the top portion back onto the bottom portion of the fuel filter canister. Hold the bottom portion again with the channel-lock pliers and twist the top part with your hand until it does not turn anymore.
Carefully position the new fuel filter into the bracket. Screw the two bracket bolts back in and tighten down with the ratchet and socket.
Hook the wire plug back into the fuel filter. Then, slide both of the fuel lines back onto the fuel filter ports. Tighten the clamps down tight with the Phillips-head screwdriver.
Put the intercooler back in place and screw the bolts back into the bolt holes on both ends of the intercooler. Tighten the bolts down tight with the ratchet and socket.
Turn the ignition key on for 15 seconds. Then, crank the engine and let it run for about 30 seconds to fill the new fuel filter up the rest of the way with diesel and to remove any air from the fuel filter housing and the fuel lines. Turn the engine off and shut the bonnet
The top portion of the fuel filter is connected to the bottom canister by an O-ring. If the new fuel filter kit comes with the O-ring, change it out. Make sure that the fuel lines are secured to the fuel filter pipes to prevent any air from entering the fuel system.
Never smoke or use open flames around diesel. Wear safety glasses when working with diesel.
Tips and warnings
- The top portion of the fuel filter is connected to the bottom canister by an O-ring. If the new fuel filter kit comes with the O-ring, change it out.
- Make sure that the fuel lines are secured to the fuel filter pipes to prevent any air from entering the fuel system.
- Never smoke or use open flames around diesel.
- Wear safety glasses when working with diesel.