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