Mitsubishi Galant/Mirage/Diamante 1990-2000

Electric Fuel Pump

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REMOVAL & INSTALLATION




CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.


NOTE
Cover all fuel hose connections with a shop towel, prior to disconnecting, to prevent splash of fuel that could be caused by residual pressure remaining in the fuel line.

1990-92 Mirage
  1. Properly relieve the fuel system pressure using proper procedures. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Drain the fuel from the fuel tank into an approved container.
  6.  


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.

  1. Lower the tank slightly and detach any remaining electrical or hose connectors at the fuel tank.
  2.  
  3. Remove the fuel tank from the vehicle as described in this section.
  4.  
  5. Remove the five nuts securing the fuel pump to the fuel tank and remove the pump assembly.
  6.  

To install:

  1. Install fuel pump into fuel tank, with new packing gasket, and tighten mounting nuts.
  2.  
  3. Install the fuel tank into the vehicle. Refer to the procedure in this section.
  4.  
  5. Lower the vehicle and pour the drained fuel into the gas tank.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Check the fuel pump for proper pressure and inspect the entire system for leaks.
  10.  

1990-93 Galant
FRONT WHEEL DRIVE (FWD)


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Fig. Loosen self-locking nuts on tank support straps to the end of the stud bolts -1990-93 FWD Galant



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Fig. Remove the six retaining bolts and gasket from the base of the tank-1990-93 FWD Galant



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Fig. Align the 3 projections on packing with the holes on the fuel pump and the nipples on the pump facing the same direction as before removal-1990-93 FWD Galant

  1. Relieve the fuel system pressure using proper procedure.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the fuel from the fuel tank into an approved gasoline container.
  8.  


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.

  1. Remove the electrical connectors at the fuel pump. Make sure there is enough slack in the electrical harness of the fuel gauge unit to allow for the fuel tank to be lowered slightly. If not, label and disconnect the electrical harness at the fuel gauge unit.
  2.  
  3. Detach the high pressure fuel line connector at the pump.
  4.  
  5. Loosen self-locking nuts on tank support straps to the end of the stud bolts.
  6.  
  7. Remove the right side lateral rod attaching bolt and disconnect the arm from the right body coupling. Lower the lateral rod and suspend from the axle beam using wire.
  8.  
  9. Remove the six retaining bolts and gasket from the base of the tank.
  10.  
  11. Remove the fuel pump assembly.
  12.  

To install:


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

  1. Align the 3 projections on packing with the holes on the fuel pump and the nipples on the pump facing the same direction as before removal.
  2.  
  3. Install the holding bolt through the bottom of the tank. Make sure the gasket on the bolt is replaced and is not pinched during installation. Torque to 10 ft. lbs. (14 Nm).
  4.  
  5. Install the right side lateral rod and attaching bolt into the right body coupling. Tighten loosely only, at this time.
  6.  
  7. Tighten the self-locking nuts on the tank support straps until the tank is fully seated. Torque the nuts to 22 ft. lbs. (31 Nm).
  8.  
  9. Install the high pressure fuel hose connector and tighten to 29 ft. lbs. (40 Nm).
  10.  
  11. Install the electrical connectors onto the fuel pump and gauge unit assemblies.
  12.  
  13. Lower the vehicle so the suspension supports the weight of the vehicle. Tighten the lateral rod attaching bolt to 58-72 ft. lbs. (80-100 Nm).
  14.  
  15. Refill the fuel tank with fuel drained during this procedure.
  16.  
  17. Connect the negative battery cable and check the entire system for proper operation and leaks.
  18.  

ALL WHEEL DRIVE (AWD)


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Fig. The fuel pump is located in the fuel tank. Remove the access cover located in the rear floor pan -1990-93 AWD Galant



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Fig. Remove the six pump retaining bolts and remove the fuel pump and gauge assembly from the tank-1990-93 AWD Galant



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Fig. Install 3M ATD Part No. 8625 or equivalent, to the rear floor pan and install the access cover into place-1990-93 AWD Galant

  1. Relieve the fuel system pressure using proper procedure.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. The fuel pump is located in the fuel tank. Remove the access cover located in the rear floor pan.
  6.  
  7. Partially drain the fuel tank into an approved gasoline container.
  8.  


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.

  1. Remove the electrical connector from the fuel pump.
  2.  
  3. Remove the overfill limiter (two-way valve), as required.
  4.  
  5. Remove the high pressure fuel hose connector.
  6.  
  7. Remove the six pump retaining bolts and remove the fuel pump and gauge assembly from the tank. Note positioning of pump prior to removal from tank.
  8.  

To install:


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

  1. Align the 3 projections on the packing with the holes on the fuel pump and the nipples on the pump facing the same direction as before removal. Install the retainers and tighten to 2 ft. lbs. (3 Nm).
  2.  
  3. Install the high pressure hose connection and tighten to 29 ft. lbs. (40 Nm).
  4.  
  5. Install the overfill limiter (two-way valve) and the electrical connector to the fuel pump.
  6.  
  7. Fill the fuel tank with the gasoline removed during this procedure.
  8.  
  9. Reconnect the negative battery cable and check the entire system for leaks.
  10.  
  11. Install 3M ATD Part No. 8625 or equivalent, to the rear floor pan and install the access cover into place.
  12.  

Diamante, 1993-00 Mirage, and 1994-98 Galant


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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.  

1999-00 Galant


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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.  

TESTING



  1. Relieve fuel system pressure.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Disconnect the fuel high pressure hose at the delivery pipe side.
  6.  


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.

  1. Connect a fuel pressure gauge to tools MD998709 and MD998742 or exact equivalent, with appropriate adapters, seals and/or gaskets to prevent leaks during the test. Install the gauge and adapter between the delivery pipe and high pressure hose. Install carefully to prevent leaks.
  2.  
  3. Connect the negative battery cable.
  4.  
  5. Apply battery voltage to the terminal for fuel pump activation (located in the engine compartment) to run the fuel pump, and check for leaks.
  6.  
  7. Start the engine and run at curb idle speed.
  8.  
  9. Measure the fuel pressure and compare to the specifications listed in the chart in .
  10.  
  11. Locate and disconnect the vacuum hose running to the fuel pressure regulator. Plug the end of the hose and record the fuel pressure again. The fuel pressure should have increased approximately 10 psi.
  12.  
  13. Reconnect the vacuum hose the fuel pressure regulator. After the fuel pressure stabilizes, race the engine 2-3 times and check that the fuel pressure does not fall when the engine is running at idle.
  14.  
  15. Check to be sure there is fuel pressure in the return hose by gently pressing the fuel return hose with fingers while racing the engine. There will be no fuel pressure in the return hose when the volume of fuel flow is low.
  16.  
  17. If fuel pressure is too low, check for a clogged fuel filter, a defective fuel pressure regulator or a defective fuel pump, any of which will require replacement.
  18.  
  19. If fuel pressure is too high, the fuel pressure regulator is defective and will have to be replaced or the fuel return is bent or clogged. If the fuel pressure reading does not change when the vacuum hose is disconnected, the hose is clogged or the valve is stuck in the fuel pressure regulator and it will have to be replaced.
  20.  
  21. Stop the engine and check for changes in the fuel pressure gauge. It should not drop. If the gauge reading does drop, watch the rate of drop. If fuel pressure drops slowly, the likely cause is a leaking injector which will require replacement. If the fuel pressure drops immediately after the engine is stopped, the check valve in the fuel pump isn't closing and the fuel pump will have to be replaced.
  22.  
  23. Relieve fuel system pressure.
  24.  
  25. Disconnect the high pressure hose and remove the fuel pressure gauge from the delivery pipe.
  26.  
  27. Install a new O-ring in the groove of the high pressure hose. Connect the hose to the delivery pipe and tighten the screws. After installation, apply battery voltage to the terminal for fuel pump activation to run the fuel pump. Check for leaks.
  28.  

 
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