Mitsubishi Outlander (2003+). Manual - part 121

FUEL TANK

FUEL SUPPLY

13C-11

REMOVAL AND INSTALLATION <4G69>

M1135001900542

Pre-removal Operation

•

Draining Fuel

•

Fuel Pump Connector Disconnection (How to Reduce 

Fuel Pressure) (Refer to GROUP 13B 

−

 On-vehicle 

Service 

P.13B-428

).

•

Centre Exhaust Pipe Removal (Refer to GROUP 15, 

Exhaust Pipe and Main Muffler 

P.15-13

).

•

Propeller Shaft Removal (Refer to GROUP 25, Propeller 

Shaft 

P.25-3

).

Post-installation Operation

•

Propeller Shaft Installation (Refer to GROUP 25, 

Propeller Shaft 

P.25-3

).

•

Centre Exhaust Pipe Installation (Refer to GROUP 15, 

Exhaust Pipe and Main Muffler 

P.15-13

).

•

Refilling Fuel

•

Checking for Fuel Leaks

AC309122AB

1

2

3

9

19

21

20

5

12

10

11

4

6

18

7

26 ± 4 N·m

2.5 ± 0.4 N·m

2.5 ± 0.4 N·m

2.5 ± 0.4 N·m

2.5 ± 0.4 N·m

13

N

14

15

N

16

N

16

10

10

10

10

12

17

17

22

7

8

Fuel tank assembly removal 
steps

1.

Fuel filler hose connection <Fuel 
filler neck side>

2.

Fuel filler neck breather hose 
connection <Fuel filler neck side>

3.

Main pipe connection

4.

Fuel vapour pipe

5.

Parking brake cable clamp 
connection <RH side>

6.

Wiring harness clamp connection 

7.

Fuel tank gauge unit assembly, fuel 
tank pomp and gauge assembly 
connector connection

<<A>>

•

Rear differential support member 
installation nuts and bolts (Refer to 
GROUP 27B 

−

 Rear Differential 

Carrier Assembly 

P.27B-16

).

<<A>>

8.

Fuel tank assembly

>>A<<

9.

Fuel high-pressure hose

10. Fuel tank hose 
11. Fuel tank vapour hose 2way valve
12. Fuel vapour pipe

>>A<<

13. Fuel pump suction tube

<<B>>

14. Fuel tank gauge unit
15. Gasket
16. Fuel tank safety valve

Fuel tank assembly removal 
steps (Continued)

FUEL TANK

FUEL SUPPLY

13C-12

17. Gasket
18. Fuel pump bracket plate

<<B>>

19. Fuel tank pump and gauge 

assembly

20. Fuel filler hose
21. Fuel filler neck breather hose
22. Fuel tank 

Fuel tank assembly removal 
steps (Continued)

AC300410AC

26

25

27

23

24

1

2

<FUEL FILLER NECK>

Fuel filler neck removal steps

1.

Fuel filler hose connection <Fuel 
filler neck side>

2.

Fuel filler neck breather hose 
connection <Fuel filler neck side>

23. Fuel filler neck protector

24. Fuel tank cap
25. Fuel filler neck
26. Fuel filler neck valve
27. Gasket

Fuel filler neck removal steps 

FUEL TANK

FUEL SUPPLY

13C-13

REMOVAL SERVICE POINTS

<<A>> REAR DIFFERENTIAL SUPPORT 
MEMBER INSTALLATION NUTS AND 
BOLTS/FUEL TANK ASSEMBLY REMOVAL

1. Remove the rear differential support member 

installation nuts and bolts, and then tilt the rear 
differential carrier assembly (Refer to GROUP 
27B 

−

 Rear Differential Carrier Assembly 

P.27B-16

).

2. Raise and support the fuel tank assembly with a 

transmission jack, and remove the mounting nuts 
and bolts.

CAUTION

Support the fuel tank assembly securely so that 
it does not fall off from the transmission jack.
3. Tilt the fuel tank assembly to disconnect the 

connectors.

4. Remove the fuel tank assembly to the direction 

shown, being careful not to strike it against the 
rear differential carrier assembly.

<<B>> FUEL TANK GAUGE UNIT/FUEL TANK 
PUMP AND GAUGE ASSEMBLY REMOVAL 

CAUTION

When withdrawing the fuel tank gauge unit, fuel 
tank pump and gauge assembly from the fuel 
tank, be careful not damage the module unit and 
the float.

INSTALLATION SERVICE POINS

>>A<< FUEL PUMP SUCTION TUBE <4WD>/FUEL 
HIGH-PRESSURE HOSE INSTALLATION

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.

AC300033AB

Fuel tank assembly

Rear differential 
carrier assembly

Tilt

Towards front 
of vehicle

AC107196

AD

Fuel tank assembly

Transaxle jack

AC300040AB

Fuel tank assembly

Rear differential 
carrier assembly

Tilt

Towards front 
of vehicle

AC300043AB

Lower

Fuel tank assembly

Rear differential 
carrier assembly

Towards front 
of vehicle

AC300047

3 mm

AE

Fuel high-pressure hose or
fuel pump suction tube

Corresponding side

Quick connector

FUEL TANK

FUEL SUPPLY

13C-14

FUEL PUMP ASSEMBLY DISASSEMBLY 
AND REASSEMBLY <2WD>

M1135004600380

REASSEMBLY SERVICE POINT

>>A<< FUEL TANK GROMMET/O-RING 
INSTALLATION
Apply gasoline on the grommet and the O-ring before 
mounting them to prevent damage or twisting.

AC309295

1

3

5

6

10

11

N

4

5

N

2

8

9

7

N

AB

Disassembly steps

1.

Gasket

2.

Fuel tank pump connector 
connection

3.

Fuel pump bracket

4.

Fuel pump hose

>>A<<

5.

O-ring

6.

Fuel pump tube

7.

Fuel pump bracket

8.

Fuel tank pump

9.

Fuel tank pump cushion

>>A<<

10. Fuel tank grommet
11. Fuel tank filter assembly

Disassembly steps (Continued)