Fuel Supply System - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL INFORMATION

This fuel system is designed with consideration for global environment protection to ensure safety at a collision, reduce weight, and improve reliability and quality. This system has the following features

1. A quick-joint connector is used for the fuel high-pressure hoses in the engine compartment to reduce the permeation of fuel evaporative emission.
2. The surface of underfloor fuel pipes is coated with 1 mm (0.04 inch) thick plastic to improve resistance to corrosion and chipping.
3. A returnless fuel system eliminates returned fuel from the engine. The heat that fuel receives from the engine is reduced, minimizing fuel temperature in the fuel tank and controlling the amount of evaporated gas < 2.0L ENGINE Non-turbo, 2.4L ENGINE. >

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Note. This figure shows LANCER body shape.

SERVICE SPECIFICATION

SERVICE SPECIFICATION

INTRODUCTION

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

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

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 the SYMPTOM PROCEDURE.
4. Verify malfunction is eliminated.

TROUBLESHOOTING HINTS (The most likely causes for this 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 (M.U.T.-III Sub Assembly) MB991824: V.C.I. MB991827: USB Cable MB991910: Main Harness A

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1. STEP 1. Using scan tool MB991958, read the MFI system diagnostic trouble code. 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 MB991910 to special tool MB991824. Connect special tool MB991910 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 M.U.T.-III system on the personal computer. Turn the ignition switch to the "ON" position. Check for MFI system diagnostic trouble code (Refer to «MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-non-turbo-except-lancer-evolution) ) < 2.0L ENGINE Non-turbo >, (Refer to «MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) ) < 2.0L ENGINE Turbo >, or (Refer to «MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-24l-except-lancer-evolution) ) < 2.4L ENGINE. > Turn the ignition switch to the "LOCK" (OFF) position, and then remove scan tool MB991958 in the reverse order of installation. Q: Is the DTC set? YES: Repair MFI system (Refer to «DIAGNOSTIC TROUBLE CODE CHART»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-non-turbo-except-lancer-evolution) ) < 2.0L ENGINE Non-turbo >, (Refer to «DIAGNOSTIC TROUBLE CODE CHART»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) ) < 2.0L ENGINE Turbo >, or ( «DIAGNOSTIC TROUBLE CODE CHART»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-24l-except-lancer-evolution) ) < 2.4L ENGINE >. Then go to Step 6 . NO: Go to Step 2.
2. STEP 2. Check the fuel pressure. Release residual pressure from the fuel line to prevent fuel spray (Refer to «FUEL PRESSURE TEST»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-non-turbo-except-lancer-evolution) ) < 2.0L ENGINE Non-turbo >, (Refer to «FUEL PRESSURE TEST»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) ) < 2.0L ENGINE Turbo >, or (Refer to «FUEL PRESSURE TEST»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-24l-except-lancer-evolution) ) < 2.4L ENGINE. > 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 main pipe and fuel high-pressure hose. Q: Are the fuel main pipe and fuel high-pressure hose in good condition? YES: Go to Step 4. NO: Repair or replace the fuel main pipe and fuel high-pressure hose. Then go to Step 6 .
4. STEP 4. Check the fuel pump module operation. Refer to «FUEL PUMP OPERATION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-non-turbo-except-lancer-evolution) < 2.0L ENGINE Non-turbo > Refer to «FUEL PUMP OPERATION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) < 2.0L ENGINE Turbo > Refer to «FUEL PUMP OPERATION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-24l-except-lancer-evolution) < 2.4L ENGINE > Q: Is the fuel pump module operation in good condition? YES: Then go to Step 5. NO: Replace the fuel pump module (Refer to «FUEL PUMP MODULE REPLACEMENT < 2.0L ENGINE NON-TURBO, 2.4L ENGINE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/fuel-system/#fuel-supply-system-except-lancer-evolution) ) or (Refer to «FUEL PUMP MODULE REPLACEMENT < 2.0L ENGINE TURBO >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/fuel-system/#fuel-supply-system-except-lancer-evolution) ). Then go to Step 6 .
5. STEP 5. Check the inside of the fuel tank for contamination and rust. Remove the fuel tank (Refer to «FUEL TANK < 2.0L ENGINE Non-turbo, 2.4L ENGINE >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/fuel-system/#fuel-supply-system-except-lancer-evolution) ) or (Refer to «FUEL TANK < 2.0L ENGINE Turbo >»(/mitsubishi/lancer-evolution/x-2007-2016/remont/fuel-system/#fuel-supply-system-except-lancer-evolution) ). 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 .

SPECIAL TOOLS

SPECIAL TOOLS Tool Tool number and name Supersession Application MB991958 Scan tool (M.U.T.-III sub assembly) MB991824 Vehicle communication interface (V.C.I.) MB991827 M.U.T.-III USB cable MB991910 M.U.T.-III main harness A (Vehicles with CAN communication system) MB991911 M.U.T.-III main harness B (Vehicles without CAN communication system) MB991914 M.U.T.-III main harness C (for Chrysler models only) MB991825 M.U.T.-III measurement adapter MB991826 M.U.T.-III trigger harness MB991824-KIT NOTE: MB991826 M.U.T.-III Trigger Harness is not necessary when pushing V.C.I. ENTER key. CAUTION: 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 code MB991658 Test harness set Tool not available Fuel tank differential pressure sensor check

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FUEL PUMP OPERATION CHECK

Refer to FUEL PUMP OPERATION CHECK < 2.0L ENGINE Non-turbo >.

Refer to FUEL PUMP OPERATION CHECK < 2.0L ENGINE Turbo >.

Refer to FUEL PUMP OPERATION CHECK < 2.4L ENGINE. >

FUEL LEVEL SENSOR CHECK

Refer to FUEL LEVEL SENSOR CHECK .

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1. Remove the rear seat cushion assembly (Refer to «REAR SEAT ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/gauges-instrument-panels/#interior-except-lancer-evolution) .)
2. Remove the floor inspection lid (LH.)
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 «HOW TO REDUCE PRESSURIZED FUEL LINES»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-non-turbo-except-lancer-evolution) ) < 2.0L ENGINE Non-turbo > or (Refer to «HOW TO REDUCE PRESSURIZED FUEL LINES»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-24l-except-lancer-evolution) .) < 2.4L ENGINE >
5. Insert a flat-tip screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04 inch) thick] into the retainer of the fuel main pipe connector. CAUTION: When pushing up the retainer of the fuel main pipe connector, pay attention to avoid damage to the retainer.
6. Turn the flat-tipped screwdriver inserted into the retainer by 90 degree angle to push up the retainer and unlock the fuel main pipe.
7. Disconnect the fuel main pipe from the fuel pump module.
8. Remove the fuel pump module mounting nuts. CAUTION: Pay attention not to damage the fuel level sensor and float of the fuel pump module when removing it from the fuel tank through the service hole.
9. Remove the fuel pump module from service hole.
10. Replace the fuel pump module gasket with a new one. CAUTION: Pay attention not to damage the fuel level sensor and the float of the fuel pump module when installing it to the fuel tank through the service hole. When installing the fuel pump module to the fuel tank, check that the float of the fuel pump module moving area moves smoothly.
11. Install the fuel pump module to the fuel tank through the service hole, and tighten the fuel pump module mounting nuts to the specified torque. Tightening torque: 2.5 ± 0.4 N.m (22 ± 4 in-lb)
12. Before the installation, push up the retainer of the fuel main pipe connector.
13. Connect the connector of fuel main pipe to the fuel pump module securely. CAUTION: When pushing in the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer. After the installation of the fuel high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.
14. Push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel pump module.
15. Connect the fuel pump module connector and fuel tank differential pressure sensor connector.
16. Install the floor inspection lid (LH.)
17. Install the rear seat cushion assembly (Refer to «REAR SEAT ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/gauges-instrument-panels/#interior-except-lancer-evolution) .)

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1. Remove the rear seat cushion assembly (Refer to «REAR SEAT ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/gauges-instrument-panels/#interior-except-lancer-evolution) .)
2. Remove the floor inspection lid (LH.)
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 «HOW TO REDUCE PRESSURIZED FUEL LINES»(/mitsubishi/lancer-evolution/x-2007-2016/remont/testing-diagnostics/#multiport-fuel-injection-mfi-20l-turbo-except-lancer-evolution) .)
5. Disconnect the fuel return hose.
6. Insert a flat-tip screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04 inch) thick] into the retainer of the fuel main pipe connector. CAUTION: When pushing up the retainer of the fuel main pipe connector, pay attention to avoid damage to the retainer.
7. Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees angle to push up the retainer and unlock the fuel main pipe.
8. Disconnect the fuel main pipe from the fuel pump module.
9. Remove the fuel pump module mounting nuts. CAUTION: Pay attention not to damage the fuel level sensor and float of the fuel pump module when removing it from the fuel tank through the service hole.
10. Disconnect the fuel tank suction hose while removing the fuel pump module from the service hole, and then remove the fuel pump module from the service hole.
11. Replace the fuel pump module gasket with a new one. CAUTION: Pay attention not to damage the fuel level sensor and the float of the fuel pump module when installing it to the fuel tank through the service hole. In addition, be careful that the float of the fuel pump module does not catch the fuel tank suction hose in the fuel tank. When installing the fuel pump module to the fuel tank, check that the float of the fuel pump module moving area moves smoothly.
12. While inserting the fuel pump module into the fuel tank from the service hole, connect the fuel tank suction hose, and install the fuel pump module to the fuel tank.
13. Tighten the fuel pump module mounting nuts to the specified torque. Tightening torque: 2.5 ± 0.4 N.m (22 ± 4 in-lb)
14. Before the installation, push up the retainer of the fuel main pipe connector.
15. Connect the connector of fuel main pipe to the fuel pump module securely. CAUTION: When pushing in the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer. After the installation of the fuel high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.
16. Push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel pump module.
17. Connect the fuel return hose.
18. Connect the fuel pump module connector and fuel tank differential pressure sensor connector.
19. Install the floor inspection lid (LH.)
20. Install the rear seat cushion assembly (Refer to «REAR SEAT ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/gauges-instrument-panels/#interior-except-lancer-evolution) .)

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1. Remove the rear seat cushion assembly (Refer to «REAR SEAT ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/gauges-instrument-panels/#interior-except-lancer-evolution) .)
2. Remove the floor inspection lid (RH.)
3. Disconnect the fuel level sensor (sub) connector. CAUTION: Pay attention not to damage the fuel level sensor (sub) and the float of the fuel level sensor (sub) when removing it from the fuel tank through the service hole.
4. Remove the fuel level sensor (sub) mounting nuts, and remove the fuel level sensor (sub) from the service hole.
5. Replace the fuel level sensor (sub) gasket with a new one. CAUTION: Pay attention not to damage the fuel level sensor (sub) and the float of the fuel level sensor (sub) when installing it to the fuel tank through the service hole. When installing the fuel level sensor (sub) to the fuel tank, check that the float of the fuel level sensor (sub) moving area moves smoothly.
6. Install the fuel level sensor (sub) 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)
7. Connect the fuel level sensor (sub) connector.
8. Install the floor inspection lid (RH.)
9. Install the rear seat cushion assembly (Refer to «REAR SEAT ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/gauges-instrument-panels/#interior-except-lancer-evolution) .)

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1. Remove the floor inspection lid (LH.)
2. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.
3. Insert a flat-tip screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04 inch) thick] into the retainer of the fuel main pipe connector. CAUTION: When pushing up the retainer of the fuel main pipe connector, pay attention to avoid damage to the retainer.
4. Turn the flat-tipped screwdriver inserted into the retainer by 90 degree angle to push up the retainer and unlock the fuel main pipe.
5. Disconnect the fuel main pipe from the fuel pump module.

Scheme 27

1. Remove the fuel tank band (LH.)
2. Hold the fuel tank assembly with the transmission jack, and remove the fuel tank band (RH.)

<< C >> FUEL FILLER HOSE CONNECTION/FUEL TANK ASSEMBLY REMOVAL

1. Hold the fuel tank assembly using the transmission jack, and remove the mounting nuts.
2. Disconnect the fuel filler hose connection, and remove the fuel tank assembly.

<< D >> RIVET REMOVAL

Use a 6.0/diameter/mm drill to make a hole in the rivet to break it, and then remove the rivet.

Scheme 28

>> A << RIVET INSTALLATION

Use a rivet tool shown in the illustration to connect the parts with rivets by the following procedures.

Scheme 29

1. Insert the rivet into a corresponding location.
2. Set the rivet tool at a portion A of rivet.
3. While pushing the flange surface of the rivet onto parts to be fixed with the rivet tool, press the handle of the tool.
4. Thin part of portion A of the rivet will be cut off and the parts is fixed in position.

>> B << HOSE CLAMP INSTALLATION

Connect the fuel filler hose, and tighten the bolt of hose clamp so that the bolt tightening dimension of the hose clump becomes 8.5 ± 1.5 mm (0.33 ± 0.06 inch.)

Scheme 30

>> C << FUEL MAIN PIPE CONNECTION

1. Before the installation, push up the retainer of the fuel main pipe connector.
2. Connect the connector of fuel main pipe to the fuel pump module securely. CAUTION: When pushing in the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer. After the installation of the fuel high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.
3. Push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel pump module.

Scheme 31

<< A >> FUEL PUMP MODULE REMOVAL

>> A << FUEL PUMP MODULE INSTALLATION

Connect the fuel filler hose, and tighten the bolt of hose clamp so that the bolt tightening dimension of the hose clump becomes 8.5 ± 1.5 mm (0.33 ± 0.06 inch.)

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< FUEL PUMP MODULE >

Note. For installation and removal, refer to FUEL PUMP MODULE REPLACEMENT in On-vehicle Service.

Scheme 33

>> A << O-RING INSTALLATION

To avoid twisting and damage, apply gasoline before installation of the O-ring.

FUEL SHUT-OFF VALVE CHECK

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

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FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK

Required Special Tool

1. MB991658: Test Harness Set

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1. Disconnect the fuel tank differential pressure sensor connector and connect special tool MB991658 between the terminals of the disconnected connector.
2. Turn the ignition switch to "ON" position and measure the voltage between terminal number 1 and ground. Standard value: 2.0 - 3.0 V

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1. Remove the floor inspection lid (LH.)
2. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.
3. Disconnect the fuel return hose.
4. Insert a flat-tip screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04 inch) thick] into the retainer of the fuel main pipe connector. CAUTION: When pushing up the retainer of the fuel main pipe connector, pay attention to avoid damage to the retainer.
5. Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees angle to push up the retainer and unlock the fuel main pipe.
6. Disconnect the fuel main pipe from the fuel pump module.

<< B >> FUEL LEVEL SENSOR (SUB) REMOVAL

1. Remove the floor inspection lid (RH.)
2. Disconnect the fuel level sensor (sub) connector.

Scheme 39

1. Support the fuel tank assembly with a transmission jack to remove the connecting bolts of fuel tank band and the connecting nuts of fuel tank assembly.
2. Lower the transmission jack slightly and disconnect the fuel filler hose.
3. Tilt the fuel tank assembly, and remove the fuel tank assembly while avoiding the rear differential carrier.

Use a 6.0/diameter/mm drill to make a hole in the rivet to break it, and then remove the rivet.

Use a rivet tool shown in the illustration to connect the parts with rivets by the following procedures.

1. Insert the rivet into a corresponding location.
2. Set the rivet tool at a portion A of rivet.
3. While pushing the flange surface of the rivet onto parts to be fixed with the rivet tool, press the handle of the tool.
4. Thin part of portion A of the rivet will be cut off and the parts is fixed in position.

Connect the fuel filler hose, and tighten the bolt of hose clamp so that the bolt tightening dimension of the hose clump becomes 8.5 ± 1.5 mm (0.33 ± 0.06 inch.)

1. Before the installation, push up the retainer of the fuel main pipe connector.
2. Connect the connector of fuel main pipe to the fuel pump module securely. CAUTION: When pushing in the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer. After the installation of the fuel high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.
3. Push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel pump module.

Scheme 40

<< A >> FUEL LEVEL SENSOR (SUB)/FUEL PUMP MODULE REMOVAL

While removing the fuel pump module from the fuel tank, disconnect the fuel tank suction hose from the fuel pump module, and remove the fuel pump module from the fuel tank.

While inserting the fuel pump module into the fuel tank from the service hole, connect the fuel tank suction hose, and install the fuel pump module to the fuel tank.

>> B << FUEL LEVEL SENSOR (SUB) INSTALLATION

>> C << HOSE CLAMP INSTALLATION

Connect the fuel filler hose, and tighten the bolt of hose clamp so that the bolt tightening dimension of the hose clump becomes 8.5 ± 1.5 mm (0.33 ± 0.06 inch).

Note. For installation and removal, refer to FUEL PUMP MODULE REPLACEMENT in On-vehicle Service.

Scheme 41

To avoid twisting and damage, apply gasoline before installation of the O-ring.

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

Required Special Tool

1. MB991658: Test Harness Set

1. Disconnect the fuel tank differential pressure sensor connector and connect special tool MB991658 between the terminals of the disconnected connector.
2. Turn the ignition switch to "ON" position and measure the voltage between terminal number 1 and ground. Standard value: 2.0 - 3.0 V

See also:
• MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
• MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
• MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS
• FUEL LEVEL SENSOR CHECK
• REAR SEAT ASSEMBLY
• FUEL PUMP MODULE REPLACEMENT < 2.0L ENGINE NON-TURBO, 2.4L ENGINE >