Mitsubishi Outlander XL. Manual - part 422

YES:

 Repair MFI system (Refer to GROUP 13Ab, Diagnostic

Trouble Code Chart P.13Ab-44). Then go to Step 6.

NO:

 Go to Step 2.

STEP 2. Check the fuel pressure.
Release residual pressure from the fuel line to prevent fuel spray
(Refer  to  GROUP  13Aa,  On-vehicle  Service  -  Fuel  Pressure
Test P.13Aa-17).

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 tube.

ZC6033310000

Fuel main pipe

Fuel high-pressure tube

Q:Are  the  fuel  main  pipe  and  fuel  high-pressure  tube  in

good condition?

YES:

 Go to Step 4.

NO:

 Repair or replace the fuel main pipe or fuel high-

pressure tube. Then go to Step 6.

STEP 4. Check the fuel pump module operation.
Refer  to  GROUP  13Aa,  On-vehicle  Service  -  Fuel  Pump
Operation Check P.13Aa-20.

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

YES:

 Go to Step 5.

NO:

 Replace the fuel pump module (Refer to P.13B-7)

<FWD>, (Refer to P.13B-9) <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  (Refer  to  P.13B-13)  <FWD>,  (Refer
to P.13B-18) <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.

FUEL SUPPLY

13B-5

FUEL SUPPLY DIAGNOSIS

SPECIAL TOOLS

M11305000006USA0000010000

Tool

Tool number and name Supersession

Application

MB991910

MB991826

MB991911

MB991914

MB991824

MB991827

MB991825

Do not use

A

B

C

D

E

F

G

Do not use

YB9919580001

MB991958

A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991914
F: MB991825
G: MB991826

M.U.T.-III sub assembly

A:

 Vehicle

communication
interface (V.C.I.)
B: M.U.T.-III USB cable
C:

 M.U.T.-III

 main

harness  A  (Vehicles
with

 CAN

communication system)
D:

 M.U.T.-III

 main

harness  B  (Vehicles
without

 CAN

communication system)
E:

 M.U.T.-III

 main

harness  C  (for  Daimler
Chrysler models only)
F:  M.U.T.-III  adapter
harness
G:  M.U.T.-III  trigger
harness

MB991824-KIT

NOTE: 

G: MB991826

M.U.T.-III
Trigger Harness
is not necessary
when pushing
V.C.I. ENTER key.

For

 vehicles

 with

 CAN

communication, use M.U.T.-III
main  harness  A  to  send
simulated  vehicle  speed.  If
you  connect  M.U.T.-III  main
harness  B  instead,  the  CAN
communication

 does

 not

function correctly.
Checking  diagnostic  trouble
codes

MB991658

MB991658
Test harness set

Tool not available

Fuel  tank  differential  pressure
sensor check

13B-6

FUEL SUPPLY

SPECIAL TOOLS

ON-VEHICLE SERVICE

FUEL PUMP OPERATION CHECK

M11305000010USA0000010000

Refer  to  GROUP  13Aa,  On-vehicle  Service  -  Fuel  Pump
Operation Check P.13Aa-20.

FUEL LEVEL SENSOR CHECK

M11305000053USA0000010000

Refer to GROUP 54A, Combination Meter - On-vehicle Service
- Fuel Level Sensor Check P.54Ab-67.

FUEL PUMP MODULE REPLACEMENT <FWD>

M11305000049USA0000010000

1.

Remove the second seat assembly (Refer to GROUP 52A,
Second  Seat  Assembly  P.52A-21)  and  turn  up  the  floor
carpet.

ZC6012310000

Floor inspection lid (LH)

2.

Remove the floor inspection lid (LH).

AC506219

ZC6012320001

Fuel pump 
module
connector

Fuel main pipe

Fuel tank differential
pressure sensor
connector

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
13Aa,  On-vehicle  Service  -  Fuel  Pump  Connector
Disconnection  (How  to  Reduce  Pressurized  Fuel  Lines)  P.
13Aa-20.]

ZC3056040000

Fuel main pipe

Retainer

Fuel pump module

Flat-tip 
screwdriver

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.

FUEL SUPPLY

13B-7

ON-VEHICLE SERVICE

ZC3056050001

Retainer

Fuel main pipe

Fuel pump module

Flat-tip screwdriver

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.

ZC6012330001

Fuel pump module

7.

Remove the mounting nuts of fuel pump module.

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.

｠

Pay attention not to damage the fuel level sensor and the
float of the fuel pump module when installing it to the fuel
tank.

｠

When  installing  the  fuel  pump  module  to  the  fuel  tank,
check  that  the  fuel  level  sensor  moving  area  moves
smoothly.

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)

ZC3056060000

Fuel main pipe

Retainer

11.

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

ZC3056070000

Retainer

Fuel pump module

Fuel main pipe

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.

13B-8

FUEL SUPPLY

ON-VEHICLE SERVICE