Mitsubishi Outlander manuals

Mitsubishi Outlander: Fuel Supply

General Information

This fuel system is designed with consideration for global environment protection to ensure safety at a collision, reduce weight, and improve reliability and quality. This system has the following features:

CONSTRUCTION DIAGRAM

<2.4L ENGINE>

Mitsubishi Outlander. Fuel Supply

Mitsubishi Outlander. Fuel Supply

<3.0L ENGINE>

Mitsubishi Outlander. Fuel Supply

Mitsubishi Outlander. Fuel Supply

Service Specification

Mitsubishi Outlander. Fuel Supply

Special Tools

Mitsubishi Outlander. Fuel Supply

Fuel Supply Diagnosis

INTRODUCTION

The fuel system is used to supply an appropriate fuel mixture to the engine. The system consists of the fuel tank, fuel filter, fuel pump and fuel pipes. An evaporative emission system is provided to prevent evaporated fuel from escaping into the atmosphere.

Engine malfunctions caused by insufficient fuel supply and evaporative emission system operation malfunctions can be caused by faults in the vapor line, fuel pipe, hose, or fuel tank pressure control valve, etc.

TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure to find most of the fuel supply faults.

1. Gather information from the customer.

2. Verify that the condition described by the customer exists.

3. Find the malfunction by following the Symptom Procedure.

4. Verify malfunction is eliminated.

SYMPTOM PROCEDURES

Inspection Procedure 1 : Engine Malfunctions Due to Insufficient Fuel Supply

TROUBLESHOOTING HINTS (The most likely causes for this case:)

DIAGNOSIS

Required Special Tools:

STEP 1. Using scan tool MB991958, read the MFI system diagnostic trouble code.

CAUTION To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958.

  1. Ensure that the ignition switch is at the "LOCK" (OFF) position.
  2. Start up the personal computer.
  3. Connect special tool MB991827 to special tool MB991824 and the personal computer.
  4. Connect special tool MB991910 to special tool MB991824.
  5. Connect special tool MB991910 to the data link connector.
  6. Turn the power switch of special tool MB991824 to the "ON" position.

    NOTE: When special tool MB991824 is energized, special tool MB991824 indicator light will be illuminated in a green color.

  7. Start the M.U.T.-III system on the personal computer.
  8. Turn the ignition switch to the "ON" position.
  9. Check for MFI system diagnostic trouble code (Refer to GROUP 13A, Diagnostic Function − How to Read and Erase Diagnostic Trouble Codes) <2.4L engine>, (Refer to GROUP 13B, Diagnostic Function − How to Read and Erase Diagnostic Trouble Codes) <3.0L engine>.
  10. Turn the ignition switch to the "LOCK" (OFF) position, and then remove scan tool MB991958 in the reverse order of installation.

Q: Is the DTC set?

YES : Repair MFI system (Refer to GROUP 13A, Diagnostic Trouble Code Chart) <2.4L engine>, (GROUP 13B, Diagnostic Trouble Code Chart) <3.0L engine>. Then go to Step 6.

NO : Go to Step 2.

Mitsubishi Outlander. Fuel Supply

STEP 2. Check the fuel pressure.

Release residual pressure from the fuel line to prevent fuel spray (Refer to GROUP 13A, On-vehicle Service − Fuel Pressure Test).

Q: Is the fuel pressure in good condition?

YES : Go to Step 5.

NO : Go to Step 3.

STEP 3. Check for bending, twisting or clogging of the fuel main pipe and fuel high-pressure hose.

Q: Are the fuel main pipe and fuel high-pressure hose in good condition?

YES : Go to Step 4.

NO : Repair or replace the fuel main pipe or fuel high-pressure hose. Then go to Step 6.

Mitsubishi Outlander. Fuel Supply

STEP 4. Check the fuel pump module operation.

Refer to GROUP 13A, On-vehicle Service − Fuel Pump Operation Check.

Q: Is the fuel pump module operation in good condition?

YES : Go to Step 5.

NO : Replace the fuel pump module <FWD>, <AWD>. Then go to Step 6.

STEP 5. Check the inside of the fuel tank for contamination and rust.

  1. Drain fuel.
  2. Remove the fuel tank <FWD>, <AWD>.

Q: Is the fuel tank in good condition?

YES : Go to Step 6.

NO : Replace the fuel filter, and clean the fuel tank and fuel line. Then go to Step 6.

STEP 6. Retest the system.

Q: Is the engine malfunction eliminated?

YES : The procedure is complete.

NO : Return to Step 1.

On-vehicle Service

FUEL PUMP OPERATION CHECK

Refer to GROUP 13A, On-vehicle Service − Fuel Pump Operation Check.

FUEL LEVEL SENSOR CHECK

Refer to GROUP 54A, Combination Meter − On-vehicle Service − Fuel Level Sensor Check.

FUEL PUMP MODULE REPLACEMENT <FWD>

1. Remove the second seat assembly and turn up the floor carpet.

2. Remove the floor inspection lid (LH).

Mitsubishi Outlander. Fuel Supply

3. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.

4. Release the fuel pressure in the fuel line. [Refer to GROUP 13A, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ]

Mitsubishi Outlander. Fuel Supply

5. Insert a flat-tip screwdriver [6mm (0.24 inch) wide and 1mm (0.04 inch) thick] into the retainer of the fuel main pipe.

Mitsubishi Outlander. Fuel Supply

6. Turn the flat-tip screwdriver about 90 degrees to push up the retainer, and disconnect the fuel main pipe from the fuel pump module.

Mitsubishi Outlander. Fuel Supply

7. Remove the mounting nuts of fuel pump module.

CAUTION Pay attention not to damage the fuel level sensor and float of the fuel pump module when removing the fuel pump module from the fuel tank.

8. Remove the fuel pump module from service hole.

9. Replace the fuel pump module gasket with a new one.

CAUTION

10.Install the fuel pump module to the fuel tank through the service hole, and tighten the mounting nuts to the specified torque.

Tightening torque: 2.5 +- 0.4 N*m (22 +- 4 in-lb)

Mitsubishi Outlander. Fuel Supply

11.Before the installation, push up the retainer of the fuel main pipe.

Mitsubishi Outlander. Fuel Supply

12.Connect the connector of fuel main pipe to the fuel pump module securely and push down the retainer of the connector to lock it firmly.

13.After the installation, slightly pull the fuel main pipe to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.

Mitsubishi Outlander. Fuel Supply

14.Connect the fuel pump module connector and fuel tank differential pressure sensor connector.

Mitsubishi Outlander. Fuel Supply

15.Install the floor inspection lid (LH).

16.Return the floor carpet to the original condition and install the second seat assembly.

Mitsubishi Outlander. Fuel Supply

FUEL PUMP MODULE REPLACEMENT <AWD>

1. Remove the second seat assembly and turn up the floor carpet.

2. Remove the floor inspection lid (LH).

Mitsubishi Outlander. Fuel Supply

3. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.

4. Release the fuel pressure in the fuel line. [Refer to GROUP 13A, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ]

Mitsubishi Outlander. Fuel Supply

5. Insert a flat-tip screwdriver [6mm (0.24 inch) wide and 1mm (0.04 inch) thick] into the retainer of the fuel main pipe.

Mitsubishi Outlander. Fuel Supply

6. Turn the flat-tip screwdriver about 90 degrees to push up the retainer, and disconnect the fuel main pipe from the fuel pump module.

Mitsubishi Outlander. Fuel Supply

7. Remove the mounting nuts of fuel pump module.

CAUTION Pay attention not to damage the fuel level sensor and float of the fuel pump module when removing the fuel pump module from the service hole.

Mitsubishi Outlander. Fuel Supply

8. While removing the fuel pump module from the fuel tank, disconnect the suction hose from the fuel pump module to remove the fuel pump module from the service hole.

9. Replace the fuel pump module gasket with a new one.

Mitsubishi Outlander. Fuel Supply

CAUTION

10.While inserting the fuel pump module into the fuel tank, connect the suction hose to the fuel pump module to install the fuel pump module to the fuel tank.

While inserting the fuel tank pump module into the fuel tank from the service hole, connect the suction hose to the fuel tank pump module to install the fuel tank pump module to the fuel tank.

11.Tighten the fuel pump module mounting nuts to the specified torque.

Tightening torque: 2.5 +- 0.4 N*m (22 +- 4 in-lb)

Mitsubishi Outlander. Fuel Supply

12.Before the installation, push up the retainer of the fuel main pipe.

Mitsubishi Outlander. Fuel Supply

13.Connect the connector of fuel main pipe to the fuel pump module securely and push down the retainer of the connector to lock it firmly.

14.After the installation, slightly pull the fuel main pipe to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.

Mitsubishi Outlander. Fuel Supply

15.Connect the fuel pump module connector and fuel tank differential pressure sensor connector.

Mitsubishi Outlander. Fuel Supply

16.Install the floor inspection lid (LH).

17.Return the floor carpet to the original condition and install the second seat assembly.

Mitsubishi Outlander. Fuel Supply

FUEL LEVEL SENSOR (SUB) REPLACEMENT <AWD>

1. Remove the second seat assembly and turn up the floor carpet.

2. Remove the floor inspection lid (RH).

Mitsubishi Outlander. Fuel Supply

3. Disconnect the fuel level sensor (sub) connector.

Mitsubishi Outlander. Fuel Supply

CAUTION Pay attention not to damage the fuel level sensor (sub) and the float of the fuel level sensor (sub) when withdrawing it from the service hole.

4. Remove the fuel level sensor (sub) mounting nuts, and remove the fuel level sensor (sub) from service hole.

5. Replace the fuel level sensor (sub) gasket with a new one.

CAUTION Pay attention not to damage the fuel level sensor (sub) and the float of the fuel level sensor (sub) when installing it to the fuel tank through the service hole.

6. Install the fuel level sensor (sub) to the fuel tank through the service hole, and tighten the mounting nuts to the specified torque.

Tightening torque: 2.5 +- 0.4 N*m (22 +- 4 in-lb)

Mitsubishi Outlander. Fuel Supply

7. Connect the fuel level sensor (sub) connector.

Mitsubishi Outlander. Fuel Supply

8. Install the floor inspection lid (RH).

9. Return the floor carpet to the original condition and install the second seat assembly.

Mitsubishi Outlander. Fuel Supply

Fuel Tank

REMOVAL AND INSTALLATION <FWD>

Pre-removal operation

Post-installation operation

<FUEL TANK>

Mitsubishi Outlander. Fuel Supply

Fuel tank removal steps

  1. Fuel pump module connector connection
  2. Fuel tank differential pressure sensor connector connection
  3. Fuel main pipe connection
  4. Fuel filler hose connection
  5. Fuel leveling hose connection
  6. Fuel tank vapor hose A connection
  7. Fuel tank vapor hose B connection
  8. Parking brake rear cable clamp connection
  9. Fuel tank band
  10. Fuel tank assembly

<FUEL TANK FILLER TUBE>

Mitsubishi Outlander. Fuel Supply

Fuel tank filler tube removal steps

  1. Fuel filler hose connection
  2. Fuel leveling hose connection
  3. Fuel tank vapor hose A connection
  4. Fuel tank vapor hose B connection
  1. Fuel vapor tube connection
  2. Fuel leveling pipe
  3. Fuel leveling hose
  4. Fuel tank filler tube assembly
  5. Fuel cap
  6. Fuel tank filler tube boots

REMOVAL SERVICE POINTS

FUEL PUMP MODULE CONNECTOR/FUEL TANK DIFFERENTIAL PRESSURE SENSOR CONNECTOR/ FUEL MAIN PIPE DISCONNECTION

1. Remove the floor inspection lid (LH).

Mitsubishi Outlander. Fuel Supply

2. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.

3. Release the fuel pressure in the fuel line. [Refer to GROUP 13A, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ]

Mitsubishi Outlander. Fuel Supply

4. Insert a flat-tip screwdriver [6mm (0.24 inch) wide and 1mm (0.04 inch) thick] into the retainer of the fuel main pipe.

Mitsubishi Outlander. Fuel Supply

5. Turn the flat-tip screwdriver about 90 degrees to push up the retainer, and disconnect the fuel main pipe from the fuel pump module.

Mitsubishi Outlander. Fuel Supply

FUEL TANK BAND/FUEL TANK ASSEMBLY REMOVAL

1. Hold the fuel tank assembly with a transaxle jack, and remove the connecting bolts of fuel tank band and the connecting nuts of fuel tank assembly.

2. Remove the fuel tank assembly.

Mitsubishi Outlander. Fuel Supply

INSTALLATION SERVICE POINT

FUEL MAIN PIPE CONNECTION

1. Before the installation, push up the retainer of the fuel main pipe.

Mitsubishi Outlander. Fuel Supply

2. Connect the connector of fuel main pipe to the fuel pump module securely and push down the retainer of the connector to lock it firmly.

3. After the installation, slightly pull the fuel main pipe to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.

Mitsubishi Outlander. Fuel Supply

DISASSEMBLY AND ASSEMBLY

<FUEL TANK ASSEMBLY>

Mitsubishi Outlander. Fuel Supply

Fuel tank removal steps

  1. Plate
  2. Fuel pump module
  3. Fuel pump module gasket
  4. Fuel filler hose
  5. Fuel leveling hose
  6. Fuel tank vapor hose A
  7. Fuel tank vapor hose B
  8. Fuel shut-off valve
  9. Fuel tank lower protector
  10. Fuel tank

REMOVAL SERVICE POINT

FUEL PUMP MODULE REMOVAL

CAUTION Pay attention not to damage the fuel level sensor and float of the fuel pump module when removing the fuel pump module from the fuel tank.

INSTALLATION SERVICE POINT

FUEL PUMP MODULE INSTALLATION

CAUTION

REMOVAL AND INSTALLATION <AWD>

Pre-removal operation

Post-installation operation

<FUEL TANK>

Mitsubishi Outlander. Fuel Supply

Fuel tank removal steps

  1. Fuel pump module connector connection
  2. Fuel tank differential pressure sensor connector connection
  3. Fuel main pipe connection
  4. Fuel level sensor (sub) connector
  5. Fuel filler hose connection
  6. Fuel leveling hose connection
  7. Fuel tank vapor hose A connection
  8. Fuel tank vapor hose B connection
  9. Parking brake rear cable clamp connection
  1. Fuel tank band
  2. Fuel tank assembly

<FUEL TANK FILLER TUBE>

Mitsubishi Outlander. Fuel Supply

Fuel tank filler tube removal steps

  1. Fuel filler hose connection
  2. Fuel leveling hose connection
  3. Fuel tank vapor hose A connection
  4. Fuel tank vapor hose B connection
  1. Fuel vapor tube connection
  2. Fuel leveling pipe
  3. Fuel leveling hose
  4. Fuel tank filler tube assembly
  5. Fuel cap
  6. Fuel tank filler tube boots

REMOVAL SERVICE POINTS

FUEL PUMP MODULE CONNECTOR/FUEL TANK DIFFERENTIAL PRESSURE SENSOR CONNECTOR/ FUEL MAIN PIPE DISCONNECTION

1. Remove the floor inspection lid (LH).

Mitsubishi Outlander. Fuel Supply

2. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.

3. Release the fuel pressure in the fuel line. [Refer to GROUP 13A, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ]

Mitsubishi Outlander. Fuel Supply

4. Insert a flat-tip screwdriver [6mm (0.24 inch) wide and 1mm (0.04 inch) thick] into the retainer of the fuel main pipe.

Mitsubishi Outlander. Fuel Supply

5. Turn the flat-tip screwdriver about 90 degrees to push up the retainer, and disconnect the fuel main pipe from the fuel pump module.

Mitsubishi Outlander. Fuel Supply

FUEL LEVEL SENSOR (SUB) CONNECTOR DISCONNECTION

1. Remove the floor inspection lid (RH).

Mitsubishi Outlander. Fuel Supply

2. Disconnect the fuel level sensor (sub) connector.

Mitsubishi Outlander. Fuel Supply

REAR DIFFERENTIAL SUPPORT MEMBER MOUNTING BOLT/FUEL TANK BAND/FUEL TANK ASSEMBLY REMOVAL

1. Remove the mounting bolts of rear differential support member and tilt the differential carrier assembly.

2. Hold the fuel tank assembly with the transaxle jack, and remove the connecting bolts of fuel tank band and the connecting nuts of fuel tank assembly.

3. Remove the fuel tank assembly in the tilt direction, paying attention not to bump it against the rear differential carrier.

Mitsubishi Outlander. Fuel Supply

Mitsubishi Outlander. Fuel Supply

INSTALLATION SERVICE POINT

FUEL MAIN PIPE CONNECTION

1. Before the installation, push up the retainer of the fuel main pipe.

Mitsubishi Outlander. Fuel Supply

2. Connect the connector of fuel main pipe to the fuel pump module securely and push down the retainer of the connector to lock it firmly.

3. After the installation, slightly pull the fuel main pipe to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.

Mitsubishi Outlander. Fuel Supply

DISASSEMBLY AND ASSEMBLY

<FUEL TANK ASSEMBLY>

Mitsubishi Outlander. Fuel Supply

Fuel tank removal steps

  1. Fuel level sensor (sub)
  2. Fuel level sensor (sub) gasket
  3. Plate
  4. Suction hose connection
  5. Fuel pump module
  6. Fuel pump module gasket
  7. Fuel filler hose
  8. Fuel leveling hose
  9. Fuel tank vapor hose A
  10. Fuel tank vapor hose B
  11. Fuel shut-off valve
  12. Fuel tank lower protector
  13. Fuel tank

REMOVAL SERVICE POINT

FUEL LEVEL SENSOR (SUB)/SUCTION HOSE/FUEL PUMP MODULE REMOVAL

CAUTION Pay attention not to damage the fuel level sensor, the float of the fuel level sensor (sub) and float of the fuel pump module when removing the fuel level sensor (sub) and fuel pump module from the fuel tank.

While removing the fuel pump module from the fuel tank, disconnect the suction hose from the fuel pump module to remove the fuel pump module from the fuel tank.

Mitsubishi Outlander. Fuel Supply

INSTALLATION SERVICE POINTS

FUEL PUMP MODULE/SUCTION HOSE INSTALLATION

CAUTION

While inserting the fuel pump module into the fuel tank, connect the suction hose to the fuel pump module to install the fuel pump module to the fuel tank.

Mitsubishi Outlander. Fuel Supply

FUEL LEVEL SENSOR (SUB) INSTALLATION

CAUTION Pay attention not to damage the fuel level sensor (sub) and the float of the fuel level sensor (sub) when installing it to the fuel tank.

INSPECTION

FUEL SHUT-OFF VALVE CHECK

Check that the flapper of the fuel shut-off valve opens and closes as shown in the illustration.

Mitsubishi Outlander. Fuel Supply

FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK

Required Special Tool:

1. Disconnect the fuel tank differential pressure sensor connector and connect special tool MB991658 between the terminals of the disconnected connector.

2. Turn the ignition switch to "ON" position and measure the voltage between terminal 1 and ground.

Standard value: 2.0 − 3.0 V

Mitsubishi Outlander. Fuel Supply

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