Fuel Supply - Sportback Mitsubishi Lancer Evolution VIII

Scheme 1

1. The fuel tank is located under the floor of the rear seats to provide increased protection and a more luggage space.
2. A fuel tank rollover valve assembly has been adopted to prevent fuel from leaking out in case of a collision.
3. A fuel pump module, including fuel pump, fuel filter and reservoir cup, has been adopted to lighten weight and improve serviceability.

INTRODUCTION TO FUEL SUPPLY DIAGNOSIS

The fuel system is used to supply an appropriate mixture to the engine. The system consists of the fuel tank, fuel filter, fuel pump and fuel pipe that each part. An evaporative emission control system is provided to prevent evaporated fuel from escaping into the atmosphere.

Engine malfunctions caused by insufficient fuel supply and evaporative emission control system operation malfunctions can be caused by faults in the vapor line, fuel pipe, hose, or fuel tank pressure control valve, etc.

FUEL SUPPLY DIAGNOSTIC TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure to find most of the fuel supply faults.

1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following (Scheme 2).
4. Verify malfunction is eliminated.

Scheme 2

TROUBLESHOOTING HINTS (THE MOST LIKELY CAUSES FOR THE CASE:)

1. Injector failed.
2. Open or shorted injector circuit, or loose connector.
3. Bent, twisted or clogged fuel pipe or hose.
4. Malfunction of the fuel pump module.

DIAGNOSIS

Required Special Tools.

1. MB991958: Scan Tool (MUT-III Sub Assembly). MB991824: Vehicle Communication Interface (V.C.I.) MB991827: MUT-III USB Cable MB991911: MUT-III Main Harness B

Scheme 3

Scheme 4

1. STEP 1. Using scan tool MB991958, read the diagnostic trouble code (DTC). CAUTION: To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958. Ensure that the ignition switch is at the "LOCK" (OFF) position. Start up the personal computer. Connect special tool MB991827 to special tool MB991824 and the personal computer Connect special tool MB991911 to special tool MB991824. Connect special tool MB991911 to the data link connector. Turn the power switch of special tool MB991824 to the "ON" position. NOTE: When special tool MB991824 is energized, special tool MB991824 indicator light will be illuminated in a green color. Start the MUT-III system on the personal computer. Turn the ignition switch to the "ON" position. Select "Interactive Diagnosis" from the start-up screen. Select "System select." Choose "MFI" from the "POWER TRAIN" tab. Select "MITSUBISHI." Select "Diagnostic Trouble Code." If a DTC is set, it is shown. Q: Is the DTC set? YES: Refer to «DIAGNOSTIC TROUBLE CODE CHART»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/testing-diagnostics/#multiport-fuel-injection-24l-sportback) . NO: Go to Step 2.
2. STEP 2. Check the fuel pressure. Refer to «FUEL PRESSURE TEST»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/testing-diagnostics/#multiport-fuel-injection-24l-sportback) . Q: Is the fuel pressure in good condition? YES: Go to Step 5 . NO: Repair or replace. Then go to Step 3.
3. STEP 3. Check for bending, twisting or clogging of the fuel pipe or hose. Q: Are the fuel pipe and hose in good condition? YES: Go to Step 4. NO: Repair or replace. Then go to Step 6 .
4. STEP 4. Check the fuel pump module operation. Refer to «FUEL PUMP OPERATION CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/testing-diagnostics/#multiport-fuel-injection-24l-sportback) . Q: Is the fuel pump module operation in good condition? YES: Go to Step 5. NO: Replace. Then go to Step 6 .
5. STEP 5. Check the inside of the fuel tank for contamination and rust. Drain fuel. Remove the fuel tank (Refer to «FUEL TANK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/fuel-system/#fuel-supply-sportback) ). 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.
6. STEP 6. Retest the system. Q: Is the engine malfunction eliminated? YES: The procedure is complete. NO: Return to Step 1 .

Scheme 5

FUEL LEVEL SENSOR CHECK

Refer to ON-VEHICLE SERVICE

Scheme 6

Scheme 7

1. Remove the rear seat cushion assembly (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/seats/#rear-seat-assembly-sportback) ).
2. Pride out the Service hole cover.
3. Disconnect the harness connector. CAUTION: Pay attention not to damage the sensor unit and the float of the fuel level sensor when withdrawing it from the service hole.
4. Remove the fuel level sensor mounting bolts and remove the fuel level sensor from service hole. NOTE: Check the fuel level sensor (Refer to «FUEL LEVEL SENSOR CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/gauges-instrument-panels/#combination-meter-assembly-sportback__fuel-level-sensor-check) ). If defective, replace it. CAUTION: Pay attention not to damage the sensor unit and the float of the fuel level sensor when inserting it from the service hole.
5. Install the fuel level sensor. Tighten the mounting nuts to the specified torque. Tightening torque: 2.5 +/- 0.5 N.m (23 +/- 4 in-lb)
6. Connect the 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™ 8513 Gromments Windshield sealer (Black)
8. Install the rear seat cushion assembly (Refer to «INSTALLATION SERVICE POINTS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/seats/#rear-seat-assembly-sportback) ).

FUEL PUMP OPERATION CHECK

Refer to FUEL PUMP OPERATION CHECK .

Scheme 8

Scheme 9

1. Remove the rear seat assembly (Refer to «INSTALLATION SERVICE POINTS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/seats/#rear-seat-assembly-sportback) .)
2. Fuel pump connector disconnection (Refer to «FUEL PUMP CONNECTOR DISCONNECTION»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/testing-diagnostics/#multiport-fuel-injection-24l-sportback) .)
3. Remove the service hole cover mounting screws to remove the cover.
4. Disconnect the fuel pump connector. NOTE: Check the fuel pump (Refer to «FUEL PUMP OPERATION CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/testing-diagnostics/#multiport-fuel-injection-24l-sportback) .) If defective, replace the fuel pump, which is incorporated in the fuel pump module.
5. Disconnect fuel high-pressure hose.
6. Remove the mounting nuts and plate, and remove the fuel pump module from the service hole. NOTE: To disassemble or assemble the fuel pump module, refer to the section " «FUEL PUMP MODULE DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/fuel-system/#fuel-supply-sportback__fuel-pump-module-disassembly-and-assembly) ".
7. Replace the fuel pump gasket.
8. Install the fuel module to the fuel tank through the service hole.
9. Install the plate to the fuel tank and tighten the mounting nuts to the specified torque. Tightening torque: 2.5 +/- 0.5 N.m (23 +/- 4 in-lb) CAUTION: Snap the fuel high-pressure hose one-touch joint into place, then pull back slightly on the hose to assure it is secure. However, the connection should have a play of approximately 3.0 mm (0.12 inch).
10. Connect the fuel pump connector, fuel high-pressure hose and fuel hose.
11. Retain the service hole cover with the screws.
12. Install the rear seat cushion assembly (Refer to «INSTALLATION SERVICE POINTS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/seats/#rear-seat-assembly-sportback) .)

Scheme 10

1. Place a drain pan, and disconnect the fuel filler neck breather hose at pipe side. NOTE: If fuel leaks from the fuel filler neck breather hose at this stage, the leveling valve may be defective.
2. Open the fuel tank filler cap, and fill the fuel tank up.
3. If fuel does not leak from the fuel tank filler neck breather hose with the fuel tank full, the leveling valve is normal. If not so, the leveling valve may be defective. Lower the fuel tank from the vehicle and replace the valve.
4. Reconnect the fuel filler neck breather hose at the pipe side.

Scheme 11

Scheme 12

Required Special Tool

1. MB991348: Test Harness Set

<< A >> DISCONNECT HARNESS CONNECTOR/FUEL WIRING HARNESS/FUEL TANK ASSEMBLY REMOVAL

Lower the tank assembly halfway to disconnect the fuel tan harness connector and fuel wiring harness.

>> A << FUEL HIGH-PRESSURE HOSE INSTALLATION

Scheme 13

FUEL PUMP MODULE DISASSEMBLY AND ASSEMBLY

Note. For removal and installation, refer to FUEL PUMP MODULE REPLACEMENT .

Scheme 14

>> A << GROMMET/O-RING INSTALLATION

Apply gasoline on the grommet and the O-ring before mounting them to prevent damage or twisting.

FUEL SHUT-OFF VALVE CHECK

Check that the flapper of the fuel shut-off valve opens and closes as shown in the illustration.

Scheme 15

Scheme 16

Scheme 17

Scheme 18

1. Shake the fuel tank rollover valve assembly up and down to check the float inside the fuel tan rollover valve assembly is not seized.
2. Obtain a container, which is full of water.
3. Invert the fuel tank rollover valve assembly, and submerge it slowly in the water while placing you fingers over the nozzle.
4. Check that no more air bubbles appears from the fuel tan rollover valve assembly, and withdraw it slowly.
5. Open the fuel tank rollover valve assembly nozzle. If no water flows out from the nozzle aperture, the valve is normal. If water flows out, the float or spring inside the fuel tank rollover valve is defective. Replace the fuel rollover valve assembly.

Scheme 19

1. Disconnect the fuel tank differential pressure sensor connector and connect special tool MB991348 between the terminals of the disconnected connector.
2. Turn the ignition switch to "ON" and measure the output voltage between terminals 2 and 3. Standard value: 2.0 - 3.0 V

FASTENER TIGHTENING SPECIFICATIONS

Fastener Tightening Specifications

Scheme 20

Scheme 21

See also:
• DIAGNOSTIC TROUBLE CODE CHART
• ON-VEHICLE SERVICE
• REMOVAL AND INSTALLATION
• FUEL LEVEL SENSOR CHECK
• FUEL TANK
• FUEL PUMP MODULE DISASSEMBLY AND ASSEMBLY