Mitsubishi Outlander (2003+). Manual - part 119

ON-VEHICLE SERVICE

FUEL SUPPLY

13C-3

CAUTION

For 4WD: Pay attention not to damage the float 
when removing and installing fuel tank pump and 
gauge assembly through the service hole.
4. Remove the mounting nuts and fuel pump bracket 

plate, and remove the fuel pump assembly 
<2WD>, fuel tank pump and gauge assembly 
<4WD> from the service hole.

5. Install the fuel pump assembly <2WD>, fuel tank 

pump and gauge assembly <4WD> to the fuel 
tank through the service hole.

6. Install the fuel pump bracket plate to the fuel tank 

and tighten the mounting nuts to the specified 
torque.

Tightening torque: 2.5 

±

 0.4 N

⋅

m

CAUTION

After connecting the fuel high-pressure hose or 
fuel pump suction tube <4WD>, slightly pull it to 
ensure that it is installed securely. Also confirm 
that there is a play approximately 3 mm.

7. Connect the fuel pump assembly <2WD> or fuel 

tank pump and gauge assembly <4WD> 
connector, fuel return hose, fuel high-pressure 
hose and fuel suction tube <4WD>.

AC107193

Fuel tank pump and 
gauge assembly

Float

Service hole

AC

AC107194AC

2.5 ± 0.4 N·m

Fuel pump braket plate

AC300047

3 mm

AC

Fuel high-pressure hose or
fuel pump suction tube <4WD>

Corresponding side

Quick connector

AC309286AB

Fuel suction 
tube <4WD>

Fuel high-pressure
hose

Fuel pump assembly <2WD> 
or fuel tank pump and gauge assembly <4WD> 
connector

Fuel return hose
<4G63>

AC102784

Service hole cover

AB

ON-VEHICLE SERVICE

FUEL SUPPLY

13C-4

8. Tighten the service hole cover mounting screws 

and install the service hole cover.

9. Install the rear seat cushion assembly. (Refer to 

GROUP 52A 

−

 Rear seat assembly 

P.52A-36

).

FUEL TANK GAUGE UNIT 
REPLACEMENT <2WD>

M1135001400398

1. Remove the rear seat cushion assembly (Refer to 

GROUP 52A 

−

 Rear Seat Assembly 

P.52A-36

).

2. Pry off the service hole cover using a flat-tipped 

screwdriver, etc.

3. Disconnect the fuel tank gauge unit harness 

connector.

CAUTION

Pay attention not to damage the gauge unit and 
the float of the fuel tank gauge unit when 
withdrawing it from the service hole.
4. Remove the fuel tank gauge unit mounting nuts 

and remove the fuel tank gauge unit from service 
hole.

CAUTION

Pay attention not to damage the gauge unit and 
the float of the fuel tank gauge unit when 
inserting it from the service hole.

5. Install the fuel tank gauge unit 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

AC107600

AC

Service hole cover

Flat-tipped screwdriver

AC107601

AC

Fuel tank gauge unit

Fuel tank gauge unit 
harness connector

AC107188

AD

Service hole

Gauge unit

Fuel tank gauge unit

AC107188

AE

Service hole

Gauge unit

Fuel tank gauge unit

AC107602

AC

2.5 ± 0.4 N·m

ON-VEHICLE SERVICE

FUEL SUPPLY

13C-5

6. Connect the fuel tank gauge unit harness 

connector.

7. Apply the specified sealant to the contact surfaces 

of the service hole cover and the floor pan, and 
install the service hole cover.

Specified sealant: 3M

ä 8513 Grommets 

Windshield Sealer (Black)

8. Install the rear seat cushion assembly (Refer to 

GROUP 52A 

−

 Rear Seat Assembly 

P.52A-36

).

FUEL TANK GAUGE UNIT 
REPLACEMENT <4WD>

M1135001400406

1. Remove the rear seat cushion assembly (Refer to 

GROUP 52A 

−

 Rear Seat Assembly 

P.52A-36

).

2. Remove the service hole cover mounting screws 

and remove the service hole cover.

3. Disconnect the fuel tank gauge unit harness 

connector and fuel pump suction tube.

CAUTION

Pay attention not to damage the gauge unit and 
the float of the fuel tank gauge unit when 
withdrawing it from the service hole.
4. Remove the fuel tank gauge unit mounting nuts 

and remove the fuel tank gauge unit from service 
hole.

AC107601

AC

Fuel tank gauge unit

Fuel tank gauge unit 
harness connector

AC100961AD

Service hole cover

Floor pan

AC107603

AC

Service hole cover

AC107189

AC

Fuel pump suction tube

Fuel tank gauge
unit harness 
connector

Fuel tank gauge unit

AC107190

AD

Service hole

Gauge unit

Float

Fuel tank gauge unit

ON-VEHICLE SERVICE

FUEL SUPPLY

13C-6

CAUTION

Pay attention not to damage the gauge unit and 
the float of the fuel tank gauge unit when 
inserting it from the service hole.

5. Install the fuel tank gauge unit 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

CAUTION

After connecting the fuel high-pressure hose or 
fuel pump suction tube, slightly pull it to ensure 
that it is installed securely. Also confirm that 
there is a play approximately 3 mm.

6. Connect the fuel tank pump gauge unit harness 

connector and fuel suction tube.

7. Tighten the service hole cover mounting screws 

and install the service hole cover.

8. Install the rear seat cushion assembly (Refer to 

GROUP 52A 

−

 Rear Seat Assembly 

P.52A-36

).

AC107190

AE

Service hole

Gauge unit

Float

Fuel tank gauge unit

AC107618

AC

2.5 ± 0.4 N·m

AC300047

3 mm

AB

Fuel high-pressure hose or
fuel pump suction tube

Main pipe nozzle or
fuel main pipe

Quick connector

AC107189

AC

Fuel pump suction tube

Fuel tank gauge
unit harness 
connector

Fuel tank gauge unit

AC107603

AC

Service hole cover