Mitsubishi Car 1999-05

Multi-Port Fuel Injection System (MFI) 1

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Fuel Pressure Regulator



Removal & Installation


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Fig. Remove the hose clamp on the fuel return line . . .



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Fig. . . . then disconnect the hose from the pressure regulator



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Fig. Remove the vacuum hose from the pressure regulator



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Fig. Remove the regulator-to-fuel rail retaining bolts, then remove the pressure regulator from the fuel rail



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Fig. Always replace the O-ring on the pressure regulator before reinstalling it

  1. Properly relieve the fuel system pressure as outlined earlier in this section.
  2.  
  3. Remove the vacuum hose from the fuel pressure regulator.
  4.  
  5. Disconnect the fuel return hose from the pressure regulator.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  6.  
  7. Remove the fuel regulator retainer bolts or remove the retaining snapring, then remove the fuel regulator from the fuel rail.
  8.  

To install:

  1. Replace the O-ring on fuel pressure regulator with a new one and coat it lightly with clean, thin oil.
  2.  
  3. Insert the regulator straight into the rail, then check that it can be rotated freely.
    NOTE
    If it does not rotate smoothly, remove it and inspect the O-ring for deformation or damage.

  4.  
  5. When properly installed, align the mounting holes. If equipped, install and tighten the retaining bolts to 8 ft. lbs. (11 Nm). If equipped, install the regulator retaining snapring.
  6.  
  7. Connect the fuel return hose to the pressure regulator.
  8.  
  9. Install the vacuum hose to the fuel pressure regulator.
  10.  
  11. Connect the negative battery cable and pressurize the fuel system. Inspect for leaks.
  12.  

Fuel Pressure Relief Valve



Removal & Installation


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Fig. Pressure relief valve location-Diamante shown, others similar



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Fig. Always install the pressure relief valve with the arrow pointing toward the EVAP canister side, not the fuel tank

  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Remove the hoses and remove the pressure relief valve.
  4.  
  5. The installation is the reverse of removal.
    NOTE
    Always install the pressure relief valve with the arrow pointing toward the EVAP canister side, not the fuel tank

  6.  

Fuel Pump



Removal & Installation


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Fig. After the seat cushion is removed, the access cover for the fuel pump is visible



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Fig. Remove the four access cover retaining screws . . .



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Fig. . . . then lift the cover from the floorpan



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Fig. On Mirage models there is a plug rather than an access cover



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Fig. Detach the electrical connector from the fuel pump



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Fig. Remove the return and feed lines from the fuel pump



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Fig. The fuel pump, just like the sending unit (shown here), is held by six retaining nuts; remove them and lift the pump out of the fuel tank



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Fig. Install 3M ATD Part No. 8625 or equivalent, to the rear floor pan and install the access cover or plug into place

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the rear seat cushion, by pulling the seat stopper outward and lifting the lower cushion upward.
  6.  
  7. Remove the access cover.
  8.  
  9. Disconnect the fuel pump wiring.
  10.  
  11. Disconnect the return hose and the high pressure fuel hose.
  12.  
  13. Remove the pump mounting nuts and remove the pump assembly.
  14.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

To install:


NOTE
If the packing material is damaged or deformed, replace it with new packing.

  1. Install the packing to the fuel tank.
  2.  
  3. Install the fuel pump assembly to the tank and tighten the retaining nuts to 22 inch lbs. (2.5 Nm).
  4.  


NOTE
Tilt the float to the left of the vehicle, when installing the pump assembly.

  1. Connect the high pressure hose, return hose and the fuel tank wiring.
  2.  
  3. Connect the negative battery cable.
  4.  
  5. Check the fuel pump for proper pressure and inspect the entire system for leaks.
  6.  
  7. Apply sealant to the access cover and install the cover.
  8.  
  9. Install the rear seat cushion.
  10.  



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Fig. Using special tool MB991480 or equivalent, remove the fuel pump retaining cap and remove the pump assembly -1999-00 Galant



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Fig. Install the packing to the fuel tank -1999-00 Galant



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Fig. Install the fuel pump assembly to the tank and align the mating marks on the pump and the floorpan -1999-00 Galant

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the rear seat cushion, by pulling the seat stopper outward and lifting the lower cushion upward.
  6.  
  7. Remove the access cover.
  8.  
  9. Disconnect the fuel pump wiring.
  10.  
  11. Disconnect the return hose and the high pressure fuel hose.
  12.  
  13. Using special tool MB991480 or equivalent, remove the fuel pump retaining cap and remove the pump assembly.
  14.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

To install:


NOTE
If the packing material is damaged or deformed, replace it with new packing.

  1. Install the packing to the fuel tank.
  2.  
  3. Install the fuel pump assembly to the tank and align the mating marks on the pump and the floorpan.
  4.  
  5. Tighten the fuel pump retaining cap using tool MB991480 or equivalent.
  6.  
  7. Connect the high pressure hose, return hose and the fuel tank wiring.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Check the fuel pump for proper pressure and inspect the entire system for leaks.
  12.  
  13. Apply sealant to the access cover and install the cover.
  14.  
  15. Install the rear seat cushion.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve fuel system pressure. Remove the fuel filler cap.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the fuel gauge cover located in the rear floor pan.
  8.  
  9. Remove the fuel pump and gauge electrical connector. Remove the overfill limiter (two-way valve).
  10.  
  11. Disconnect both sides of the high pressure fuel hose.
  12.  
  13. Remove the fuel pump and gauge assembly from the tank.
  14.  

To install:

  1. Align the three projections on the packing with the holes on the fuel pump and the nipples on the pump facing the same direction as before removal.

    Click image to see an enlarged view

    Fig. Align the positioning projections

  2.  
  3. Temporarily tighten the flare nut on the high pressure hose by hand. Making sure the hose does not twist, tighten body side nut to 22 ft. lbs. (30 Nm) and the fuel pump side nut to 25 ft. lbs. (35 Nm).
  4.  
  5. Install the overfill limiter (2-way valve) with the long shouldered side of the valve facing the canister.
  6.  
  7. Connect the electrical connector to the pump assembly.
  8.  
  9. Reconnect the negative battery cable and check the entire system for leaks.
  10.  
  11. Install sealer to the rear floor pan and install the cover into place.
  12.  

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the left rear wheel well liner, if equipped.
  6.  
  7. Disconnect the center exhaust system from the main muffler. Disconnect the rear exhaust hangers, lower the exhaust and secure aside.
  8.  
  9. Remove the tank drain plug and drain the fuel into an approved container.
  10.  
  11. Remove or disconnect the following:

    Fuel return hose, high pressure hose and vent hose from the sending unit
     
    Electrical connector
     
    Filler and vent hoses. Place a support under the tank and remove the retaining nuts.
     

  12.  
  13. Lower the tank from the vehicle.
  14.  
  15. Remove the fuel pump retaining nuts and remove the assembly from the tank.
  16.  

To install:

  1. Install or connect the following:

    Pump assembly to the tank and tighten the retaining nuts to 24 inch lbs. (3 Nm)
     
    Fuel tank and connect the filler and vent hoses. Tighten the tank retaining nuts and bolts to 19 ft. lbs. (26 Nm).
     
    Return hose, high pressure hose and all other hoses and connectors connected to the pump/sending unit
     
    Power cylinder unit and tighten the mounting bolts to 31 ft. lbs. (43 Nm), if equipped with 4WS
     
    Exhaust pipe and secure the rear hangers
     
    Left rear wheel well liner, if removed
     

  2.  
  3. Lower the vehicle and return fuel to the gas tank.
  4.  
  5. Connect the negative battery cable and check the entire system for proper operation and leaks.
  6.  

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

    Negative battery cable
     
    Rear seat cushion by pulling the seat stopper near the floor and lifting the cushion up
     
    Inspection cover on the right side of the vehicle
     
    Harness connector and the fuel lines
     
    Fuel pump assemble from the tank. Remove the locking ring on the All Wheel Drive (AWD) model.
     

  4.  

To install:

  1. Install or connect the following:

    Fuel pump in the tank
     
    Hoses and the harness connector
     
    Inspection cover
     
    Rear seat
     
    Negative battery cable
     

  2.  



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Fig. Using special tool MB991480 or equivalent, remove the fuel pump retaining cap and remove the pump assembly -Galant



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Fig. Install the packing to the fuel tank - Galant



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Fig. Install the fuel pump assembly to the tank and align the mating marks on the pump and the floorpan - Galant

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the rear seat cushion, by pulling the seat stopper outward and lifting the lower cushion upward.
  6.  
  7. Remove the access cover.
  8.  
  9. Disconnect the fuel pump wiring.
  10.  
  11. Disconnect the return hose and the high pressure fuel hose.
  12.  
  13. Using special tool MB991480 or equivalent, remove the fuel pump retaining cap and remove the pump assembly.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  14.  

To install:


NOTE
If the packing material is damaged or deformed, replace it with new packing.

  1. Install the packing to the fuel tank.
  2.  
  3. Install the fuel pump assembly to the tank and align the mating marks on the pump and the floorpan.
  4.  
  5. Tighten the fuel pump retaining cap using tool MB991480 or equivalent.
  6.  
  7. Connect the high pressure hose, return hose and the fuel tank wiring.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Check the fuel pump for proper pressure and inspect the entire system for leaks.
  12.  
  13. Apply sealant to the access cover and install the cover.
  14.  
  15. Install the rear seat cushion.
  16.  

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect the following:

    Rear seat assembly
     
    Retainer screws and service hole cover
     
    Harness electrical connector
     
    Fuel lines
     
    Fuel pump module mounting nuts
     
    Fuel pump module
     

  6.  
  7. Disassemble the fuel pump module as necessary. Refer to the accompanying figure.
  8.  
  9. Installation is the reverse of the removal procedure. Torque the fuel pump module nuts to 23 inch lbs. (2.5 Nm).

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump module-Lancer

  10.  

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the fuel from the fuel tank into an approved container.
  8.  
  9. Disconnect the filler and vent hoses.
  10.  
  11. Support the tank with a transmission jack. Disconnect the retainer straps and lower the tank to gain access to the fitting on top of the tank.
  12.  
  13. Remove or disconnect the following:

    Return hose, high pressure hose and vapor hoses from the pump/sending unit
     
    Electrical connectors at the pump/sending unit
     
    Fuel tank from the vehicle
     
    Access plate to the fuel tank and remove the pump assembly
     

  14.  

To install:

  1. Install fuel pump into fuel tank, with new packing gasket, and tighten mounting nuts.
  2.  
  3. Raise the tank in position under the vehicle.
  4.  
  5. Attach all connections to the top of the tank.
  6.  
  7. Raise the tank completely and position the retainer straps around the fuel tank. Install new fuel tank self-locking nuts and tighten to 22 ft. lbs. (31 Nm).
  8.  
  9. Connect the return hose and high pressure hoses.
  10.  
  11. Install the vapor hose and the filler hose. Install the filler hose retainer screws to the fender, if removed.
  12.  
  13. Lower the vehicle and pour the drained fuel into the gas tank.
  14.  
  15. Connect the negative battery cable. Check the fuel pump for proper pressure and inspect the entire system for leaks.
  16.  

 
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