Mitsubishi Outlander 2003-06

Testing

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Float Height Check



AWD Models
  1. Remove the fuel pump module, as outlined in the Fuel System Section.
  2.  
  3. Remove the fuel level sensor.
  4.  
  5. Move the float and measure height A at point "F" (highest) and B at point "E" (lowest) with the float arm touching stopper. Standard value:
    1. Fuel pump module & fuel level sensor:

      A: 36.7 mm (1.44 inches)
       
      B: 150 mm (5.91 inches)
       

    2.  
    3. Fuel level sensor:

      A: 20.8 mm (0.82 inch)
       
      B: 193.8 mm (7.63 inches)2. Adjust the float arm to the standard value, then go to the thermistor check.

      Click image to see an enlarged view

      Fig. Float height check-AWD models

       

    4.  

  6.  

FWD Models
  1. Remove the fuel pump module, as outlined in the Fuel System Section.
  2.  
  3. Remove the fuel level sensor.
  4.  
  5. Move the float and measure height A at point "F" (highest) and B at point "E" (lowest) with the float arm touching stopper. Standard value:
    1. A: 35.4 mm (1.39 inches)
    2.  
    3. B: 186.7 mm (7.35 inches)
    4.  

  6.  
  7. Adjust the float arm to the standard value, then go to the thermistor check.

    Click image to see an enlarged view

    Fig. Float height check-FWD models

  8.  

Resistance Test



AWD Models
  1. Remove the fuel pump module, as outlined in the Fuel System Section.
  2.  
  3. Remove the fuel level sensor.
  4.  
  5. Check that resistance value between the fuel gauge terminal and ground terminal is at the standard value when the fuel level sensor float is between point "F" (highest) and point "E" (lowest). Standard value:
    1. Point "F": 1.0 - 2.0 ohms
    2.  
    3. Point "E": 53.5 - 56.5 ohms
    4.  

  6.  
  7. Check that resistance value changes smoothly when the float moves slowly between point "F" (highest) and point "E" (lowest).
  8.  
  9. If all checks are correct, go to fuel level sensor float height check. If any check is not correct, replace the fuel level sensor.

    Click image to see an enlarged view

    Fig. Fuel level sensor resistance test-FWD models

  10.  

FWD Models
  1. Remove the fuel pump module, as outlined in the Fuel System Section.
  2.  
  3. Remove the fuel level sensor.
  4.  
  5. Check that resistance value between the fuel gauge terminal and ground terminal is at the standard value when the fuel level sensor float is between point "F" (highest) and point "E" (lowest). Standard value:
    1. Point "F": 2.2 - 3.8 ohms-
    2.  
    3. Point "E": 107.5 - 112.5 ohms-
    4.  

  6.  
  7. Check that resistance value changes smoothly when the float moves slowly between point "F" (highest) and point "E" (lowest).
  8.  
  9. If all checks are correct, go to fuel level sensor float height check. If any check is not correct, replace the fuel level sensor.

    Click image to see an enlarged view

    Fig. Fuel level sensor resistance test-FWD models

  10.  

 
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