Mitsubishi Car 1999-05

Removal & Installation

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On most vehicles covered by this manual, the fuel filter is located in the engine compartment, mounted to the firewall.


CAUTION
Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the injection system and could fail, causing personal injury or damage to the vehicle. Use only hoses and clamps specifically designed for fuel injection systems.

  1. Properly relieve the fuel system pressure as outlined in Section 5 of this manual.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. On most models, the job is made easier if the air inlet hose and upper air cleaner housing is removed from the vehicle.
  6.  


NOTE
Wrap shop towels around the fitting that is being disconnected to absorb residual fuel in the lines.

  1. Cover the hose connection with shop towels to prevent any splash of fuel that could be caused by residual pressure in the fuel pipe line. Hold the fuel filter nut securely with a backup wrench, then remove the banjo bolt on the engine feed line. Disconnect the high-pressure fuel line from the filter. Remove and discard the gaskets.
  2.  



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Fig. Use a back-up wrench on the fuel filter nut when loosening the banjo-bolt on the engine feed line

  1. While holding the fuel filter nut securely with a back-up wrench, loosen the filter feed pipe flare nut on the bottom of the filter. Separate the flare nut connection from the filter. If equipped, remove and discard the gaskets.
  2.  



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Fig. After the banjo-bolt is loose, remove it from the fuel filter



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Fig. Make sure to replace the copper washers on the banjo-bolt fitting



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Fig. Make sure to use a back-up wrench when unfastening the main fuel pipe also



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Fig. Remove the two filter bracket retaining bolts . . .



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Fig. . . . then remove the filter from the vehicle

  1. Remove the mounting bolts and remove the fuel filter. If necessary, remove the fuel filter bracket.
  2.  

To install:

  1. Install the filter to its bracket only finger-tight. Movement of the filter will ease attachment of the fuel lines.
  2.  


WARNING
Ensure that the filter is installed with the flow arrow in the proper direction. The flow arrow typically points toward the engine side of the filter. Improper installation of the fuel filter will cause the vehicle to run poorly.


NOTE
Make sure new O-rings are installed prior to installation.

  1. Insert the filter feed pipe to the lower connection of the filter and manually screw in the main pipe's flare nut.
  2.  
  3. While holding the fuel filter nut with a back-up wrench, tighten the banjo bolt to 22 ft. lbs. (30 Nm). Tighten the flare nut to 25 ft. lbs. (35 Nm), with a back-up wrench on the nut.
  4.  
  5. Tighten the filter mounting bolts to 10 ft. lbs. (14 Nm).
  6.  
  7. Connect the negative battery cable. Turn the key to the ON position to pressurize the fuel system and check for leaks.
  8.  
  9. If repairs of a leak are required, remember to release the fuel pressure before opening the fuel system.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    The filter is located in the engine compartment, mounted on the inner fender panel.

  6.  
  7. Remove the air cleaner assembly and intake hoses. Remove the battery and battery tray.
  8.  
  9. Remove the fuel lines from the filter.
  10.  
  11. Remove the mounting bolts and remove the fuel filter from the vehicle.
  12.  

To install:


NOTE
Install new gaskets or O-rings whenever fuel connections have been disassembled.

  1. Install the filter to its bracket finger-tight. Movement of the filter will ease attachment of the fuel lines.
  2.  
  3. Install new gaskets and connect the high pressure hose and eye bolt, then the main pipe and eye bolt. Tighten the eye bolts to 22 ft. lbs. (30 Nm). Tighten the flare nut to 25 ft. lbs. (35 Nm).
  4.  
  5. Tighten the mounting bolts fully.
  6.  
  7. Install the air cleaner assembly, battery and battery tray.
  8.  
  9. Connect the negative battery cable, install the fuel filler cap, turn the key to the ON position to pressurize the fuel system and check for leaks.
  10.  


NOTE
The fuel filter is located in the engine compartment.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air intake hose and the battery
     
    Fuel lines from the filter
     
    Mounting bolts and the fuel filter from the vehicle
     

  4.  

To install:

  1. If equipped with flare fitting, tighten the fitting by hand before installing the filter to the vehicle.
  2.  
  3. Install or connect the following:

    Filter to its bracket finger-tight
     
    New gaskets and connect the high pressure hose and eye bolt, then the main pipe. Tighten the eye bolts to 22 ft. lbs. (30 Nm). Tighten the flare nut to 27 ft. lbs. (37 Nm).
     

  4.  
  5. Tighten the filter mounting bolts fully.
  6.  
  7. Install or connect the following:

    Air intake hose
     
    Battery
     
    Negative battery cable, install the fuel filler cap, turn the key to the ON position to pressurize the fuel system and check for leaks.
     

  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. On models equipped with the 2.4L engine, remove the battery and the air intake hose.
  8.  
  9. Remove the fuel lines from the filter.
  10.  
  11. Remove clamp and the hose from the fuel pressure regulator.
  12.  
  13. Remove or disconnect the following:

    Fuel filter mounting bracket bolts and remove the fuel filter
     
    Bracket screw and remove the fuel filter from the mounting bracket
     

  14.  
  15. On 2.0L non-turbo models, remove the following from the filter:
    1. The eye bolt and washer.
    2.  
    3. The fuel connector and washer with the fuel pressure regulator.
    4.  

  16.  

To install:

  1. On 2.0L non-turbo models, install the fuel connector with the fuel pressure regulator to the filter with 2 new washers and tighten the eye bolt to 22 ft. lbs. (36 Nm).
  2.  
  3. Install or connect the following:

    Fuel filter to the mounting bracket with the screw
     
    Fuel filter to the vehicle with the bracket mounting bolts
     
    Main fuel pipe to the fuel filter connector or the filter itself. Torque the flare nut to 27 ft. lbs. (36 Nm).
     

  4.  
  5. On the 2.0L non-turbo engine models reconnect the hose and clamp to the fuel pressure regulator.
  6.  
  7. Reconnect the high pressure fuel hose to the fuel filter. Torque the eye bolt to 22 ft. lbs. (29 Nm).
  8.  
  9. On 2.4L engine models, install the battery and the air intake hose.
  10.  
  11. Reconnect the negative battery cable, start the engine and check for fuel leaks.
  12.  

 
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