Mitsubishi Outlander (2003+). Manual — part 116

ON-VEHICLE SERVICE

FUEL SUPPLY

13B-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

É

8513 Grommets

Windshield Sealer (Black)

8. Install the rear seat cushion assembly (Refer to

GROUP 52A

-

Rear Seat Assembly

3

52A

).

FUEL TANK GAUGE UNIT
REPLACEMENT <4WD>

M1135001400280

1. Remove the rear seat cushion assembly (Refer to

GROUP 52A

-

Rear Seat Assembly

3

52A

).

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 with-
drawing it from the service hole.

4. Remove the fuel tank gauge unit mounting nuts

and remove the fuel tank gauge unit from service
hole.

AC107601AC

Fuel tank gauge unit

Fuel tank gauge unit
harness connector

AC100961AD

Service hole cover

Floor pan

AC107603AC

Service hole cover

AC107189AC

Fuel pump suction tube

Fuel tank gauge
unit harness
connector

Fuel tank gauge unit

AC107190AD

Service hole

Gauge unit

Float

Fuel tank gauge unit

ON-VEHICLE SERVICE

FUEL SUPPLY

13B-6

CAUTION

Pay attention not to damage the gauge unit and
the float of the fuel tank gauge unit when insert-
ing 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

¼

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

3

52A

).

AC107190 AE

Service hole

Gauge unit

Float

Fuel tank gauge unit

AC107618AC

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

AC107189AC

Fuel pump suction tube

Fuel tank gauge
unit harness
connector

Fuel tank gauge unit

AC107603AC

Service hole cover

FUEL TANK

FUEL SUPPLY

13B-7

FUEL TANK

REMOVAL AND INSTALLATION

M1135001900401

Pre-removal Operation

œ

Draining Fuel

œ

Fuel Pump Connector Disconnection (How to Reduce
Fuel Pressure) (Refer to GROUP 13A

-

On-vehicle Serv-

ice

3

13A

).

œ

Centre Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler

3

15



).

œ

Propeller Shaft Removal <4WD> (Refer to GROUP 25,
Propeller Shaft

3

25

).

Post-installation Operation

œ

Propeller Shaft Installation <4WD> (Refer to GROUP 25,
Propeller Shaft

3

25

).

œ

Centre Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler

3

15



).

œ

Refilling Fuel

œ

Checking for Fuel Leaks

AC212356

1

2

3

4

11

22

24

23

6

5

8

21

8

7

26 ± 4 N·m

25

2.5 ± 0.4 N·m

2.5 ± 0.4 N·m

2.5 ± 0.4 N·m

2.5 ± 0.4 N·m

26 ± 4 N·m

13

14

<2WD>

12

15

N

N

17

19

N

19

18

AB

13

13

13

15

20

20

13

9

FUEL TANK

FUEL SUPPLY

13B-8

AC212516AB

1

2

3

4

11

22

24

23

6

15

13

14

5

7

21

8

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

<4WD>

12

16

N

17

18

N

19

N

19

13

13

13

13

15

20

20

25

8

10

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.

Return pipe

5.

Fuel vapour pipe

6.

Parking brake cable clamp
connection <RH side>

7.

Wiring harness clamp connection

8.

Fuel tank gauge unit assembly, fuel
pump assembly <2WD>, fuel tank
pomp and gauge assembly <4WD>
connector connection

<<A>>

œ

Rear differential support member
installation nuts and bolts <4WD>
(Refer to GROUP 27B

-

Rear

Differential Carrier Assembly

3

27B

).

9.

Fuel tank assembly <2WD>

<<A>>

10. Fuel tank assembly <4WD>

>>A<<

11. Fuel high-pressure hose
12. Fuel return hose
13. Fuel tank hose
14. Fuel tank vapour hose 2way valve
15. Fuel vapour pipe

>>A<<

16. Fuel pump suction tube <4WD>

<<B>>

17. Fuel tank gauge unit
18. Gasket
19. Fuel tank safety valve
20. Gasket
21. Fuel pump bracket plate

<<B>>

22. Fuel pump assembly <2WD>, fuel

tank pump and gauge assembly
<4WD>

23. Fuel filler hose
24. Fuel filler neck breather hose
25. Fuel tank

Fuel tank assembly removal
steps

&RQWLQXHG