MITSUBISHI DIAMANTE 1900 Repair Manual

5-4 FUELSYSTEM
93155422 Fig. 12 Exploded view of the throttle body
and related components-l .5L engine
15-Z Nm
11-16 lt.lbs. 15-22 Nm 11-16 ft.lbr.
1. Connectnn for accelerator cable
2. Connection for breather hose
3 Connection for au intake hose
4 Connectton for au hose C
5. Connectton for vacuum hose
6 Connectton for IAC motor connector and
closed throttle posItIon swtch connector
7 ConnectIon for TPS connector
8 Connectton for water hose
9 Connectnon for water by-pass hose
10 Ground plate mounting screw
11. Throttle body stay and ground plate
12 Au flttlng
13 Gasket
14 Throttle body
15 Gasket ’
89575422 :ig. 14 Exploded view of the throttle body and related components-l.61 and 2.OL DOHC en-
line
93155g24 Yg. 15 Exploded view of the throttle body and related components- :ig. 16 Exploded view of the throttle body and related components-
1.OL SOHC engine, DOHC similar
1.5L engine
4. Remove the connection for the breather hose
10. Unfasten the throttle body mounting bolts, 14. If equipped, install the throttle body stay and
and the air intake hose from the throttle body and po-
then remove the throttle body from the engine. Re- QrOUnd plate. Secure with retainers tightened to
sition aside.
move and discard the gasket. 11-16 ft. Ibs. (15-22 Nm).
5. Tag and disconnect the necessary vacuum
To install: 15. Install the ground plate mounting screw.
hoses.
11. Clean all old gasket material from the both 16. Connect the water hoses to the throttle body.
6. Label and detach the electrical connectors at throttle body mounting surfaces. Install new gasket Install new hose clamps if required.
the throttle body, as necessary.
1 onto the intake manifold plenum mounting surface. 17. Attach the electrical and vacuum connectors
7. Disconnect the water and water by-pass
*Poor idling quality and poor performance to the throttle body, as tagged during removal.
hoses at the base of the throttle body.
may be experienced if the gasket is installed 18 Connect the accelerator cable to the throttle
8. If equipped, unfasten the ground plate
incorrectly. body and install the adjusting bolt in original posi-
mounting screws, then remove the throttle body stay
tion. Check adjustment of cable.
and QrOUnd plate from the engine.
12. Install the throttle body to the intake manifold 19 Install the air intake and breather hoses.
9. Remove the air fitting and
gasket. plenum and tighten the mounting bolts. 20. If removed, install the battery and connect the
13. Install the air fitting, if equipped, making sure positive cable.
new gasket iS in place.

FUEL SYSTEM 5-5,
21. Connect the negative battery cable. Refill the
cooling system.
REMOVAL & INSTALLATION
1.5L, 1.8L, And 2.OL SOHC Engines
ti See Figures 17, 18, and 19
1. Relieve the fuel system pressure as described
in this section.
2. Disconnect the PCV hose from the valve
cover. Also disconnect the breather hose at the oppo-
site end of the valve cover.
3. Remove the bolts holding the high pressure
fuel line to the fuel rail and disconnect the line. Be
prepared to contain fuel spillage; plug the line to
keep out dirt and debris.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. 00 not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
4. Remove the vacuum hose from the fuel pres-
sure regulator.
5. Disconnect the fuel return hose from the
pressure regulator.
6. Label and detach the electrical connectors
from each injector.
7. Remove the bolt(s) holding the fuel rail to the
manifold. Carefully lift the rail up and remove it with
the injectors attached. Take great care not to drop an
injector Place the rail and Injectors in a safe location
on the workbench; protect the tips of the injectors
from dirt and/or Impact.
8. Remove and discard the injector rnsulators
from the intake manifold. The insulators are not
reusable.
9. Remove the injectors from the fuel rail by
pulling gently in a straight outward motion. Make
certain the grommet and O-ring come off with the in-
jector.
To install: 10. Install a new insulator in each injector port in
the manifold.
11. Remove the old grommet and O-ring from
each injector Install a new grommet and O-ring; coat
the O-ring lightly with clean, thin oil.
12. If the fuel pressure regulator was removed,
replace the O-ring with a new one and coat it lightly
with clean, thin oil Insert the regulator straight into
the rail, then check that it can be rotated freely. If It
does not rotate smoothly, remove it and inspect the
O-ring for deformation or jamming. When properly
installed, align the mounting holes and tighten the
retaining bolts to 7 ft. Ibs. (9 Nm). This procedure
must be followed even if the fuel rail was not re-
moved.
13. Install the injector into the fuel rail, constantly
turning the injector left and right during installation.
1Hilt4naunfu(norc e Fu(l
:E%!,,.,.- 1: IEE
: Efgz tz!z? :: %%I
;P&.xmeaw 13 m
Fig. 17 Exploded view of the fuel injectors and related components-l .5L engine
I
.xs.
1 Connection for breather hose
2 Connection for PCV hose
3 Connection for high tm?ss”re fuel hose
4 0-ring
5 Connection for vacuum hose
6 Connecr~on for fuel return hose
7 Fuel pressure regulator
8 0-ring
9 Connection for control harness
10 Fuel ml
11 Insulator
12 insulator
13 lnlector
14 O-ring
15 Grommet
89575026
Fig. 19 Exploded view of the fuel injectors and related components-2.01 SOHC engine
When fully installed, the injector should still turn
freely in the rail. If it does not, remove the injector
and inspect the O-ring for deformation or damage.
14. Install the delivery pipe and injectors to the
engine. Make certain that each injector fits correctly
into its port and that the rubber insulators for the fuel
rail mounts are in position. 15. Install the fuel rail retaining bolts and tighten
* them to 9 ft. Ibs. (12 Nm).
16. Connect the wiring harnesses to the appro-
priate injector.
17. Connect the fuel return hose to the pressure
regulator, then connect the vacuum hose.
18. Replace the O-ring on the high pressure fuel
line, coat the O-ring lightly with clean, thin oil and

install the line to the fuel rail. Tighten the mounting
bolts,
19. Attach the PCV hose and the breather hose if
thev were disconnected.
20. Connect the negative battery cable. Pressur-
ize the fuel system and inspect all connections for
I
leaks.
1.6L and 2.01 DOHC Engines
b See Figure 20
1. Relieve the fuel system pressure as described
in this section.
2. Disconnect the negative battery cable.
3. Wrap the connection with a shop towel and
disconnect the high pressure fuel line at the fuel rail.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
* tainers to avoid the possibility of fire or ex-
plosion.
4. Disconnect the fuel return hose and remove
the O-ring.
5. Disconnect the vacuum hose from the fuel
pressure regulator.
6. Disconnect the PCV hose. On 2.OL engine,
remove the center cover.
1 x Connection for PCV hose
2. Connection for high pressure fuel hose
3. O-ring
4. Connection for vacuum hose
5. Connection for fuel return hose
&2 I=, 1c.1 nrncc*.ra regu,ator
lble clamD
7. Label and detach the electrical connectors
from each iniector.
8. Accelerator ca
9. Center cover . 10. Connection for control harness
11 Fuel rail
12. Insulator
13. Insulator
14. Injector
15. O-ring
16. Grommet
89575g27 Exploded view of the fuel injectors and related
components -1.6L and 2.QL DOHC
5-6 FUELSYSTEM
8. Remove the injector rail retaining bolts, Make
sure the rubber mounting bushings do not get lost.
9. Lift the rail assembly up and away from the
engine.
10. Remove the injectors from the rail by pulling
gently. Discard the lower insulator. Check the resis-
tance through the injector. The specification for 2.OL
turbocharged engine is 2-3 ohms at 70°F (20°C).
The specification for the others is 13-15 ohms at
70°F (20°C). To install:
11. Install a new grommet and O-ring to the in-
jector. Coat the O-ring with light oil.
12. install the injector to the fuel rail.
13. Replace the seats in the intake manifold. In-
stall the fuel rail and injectors to the manifold. Make
sure the rubber bushings are in place before tighten-
ing the mounting bolts.
14. Tighten the retaining bolts to 72 inch lbs. (11
Nm).
Fig. 21 Remove the fuel feed line-to-fuel
rail retaining fitting bolts . . .
15. Attach the connectors to the injectors and in-
stall the center cover. Connect the PCV hose.
16. Connect the fuel pressure regulator vacuum
hose.
17. Connect the fuel return hose.
18. Replace the O-ring, lightly lubricate it and
connect the high pressure fuel line.
19. Connect the negative battery cable and check
the entire system for proper operation and leaks. Fig. 22 . . . then remove the fuel feed line
from the fuel injector rail
2.4L Engine
b See Figures 21 thru 30

FUELSYSTEM 5-7
Fig, 25 Remove the vacuum hose from the Fig. 25 Detach the connectors from all of
pressure regulator the fuel injectors
1 H; :A ..;lt;;aft~rgi,i~;yl the ;F: 1 / . 93155p15 1 Fig 29 Remove the fuel injectors from the
tall by gently rocking them loose Fig. 27 Remove the two fuel rail retaining
bolts . . .
93155ps Fig. 30 Always replace the O-rings on the
injectors before reinstalling them
1. Relieve the fuel system pressure as described
in this section.
2. Label and disconnect the spark plug wires. ’
Position the wires aside.
3. Disconnect the PCV hose from the valve
cover,
4. Remove the bolts holding the high pressure
fuel line to the fuel rail, then disconnect the line. Be
prepared to contain fuel spillage; plug the line to on the workbench; protect the tips of the injectors
from dirt and/or impact.
9. Remove and discard the injector insulators
from the intake manifold. The insulators are not
reusable.
10. Remove the injectors from
pulling gently in a straight outwarc the fuel rail by
I motion. Make cer-
tain the grommet and O-ring come off with the injector. 18. Connect the fuel return hose to the pressure
regulator, then connect the vacuum hose.
19. Replace the O-ring on the high pressure fuel
line, coat the O-ring lightly with clean, thin oil and
install the line to the fuel rail. Tiahten the mountina
To install: -
the fuel system and inspect all connections for leaks. bolts to 4 ft. Ibs. (6 Nm).
20. Connect the PCV hose and spark plug wires.
21. Connect the negative battery cable. Pressurize
1. neneve me rueI system pressure.
2. Disconnect the negative battery cable. 3.OL and 3.5L Engines
# See Figures 31 and 32
> - ,. .* , ,
I
I
Work MUST NOT be started until at least 90
seconds after the ignition switch is turned to
the LOCK position and the negative battery
cable is disconnected from the battery. This
will allow time for the air bag system backup
power supply to deplete its stored energy,
preventing accidental air bag deployment
which could result in unnecessary air bag
system repairs and/or personal injury.
3. Drain the cooling system.
4. Disconnect all components from the air in-
take plenum and remove the plenum from the intake
manifold. Refer to Section 3.
5. Wrap the connection with a shop towel and
disconnect the high pressure fuel line at the fuel rail. keep out dirt and debris.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possfbility of fire or ex-
plosion.
5. Remove the vacuum hose from the fuel pres-
sure regulator.
6. Disconnect the fuel return hose from the
pressure regulator.
7. Label and detach the electrical connectors
from each injector.
8. Remove the bolt(s) holding the fuel rail to the
manifold. Carefully lift the rail up and remove it with
the injectors attached. Take great care not to drop an
injector. Place the rail and injectors in a safe location 11. Install a new insulator in each injector port in
the manifold.
12. Remove the old grommet and D-ring from
each injector. Install a new grommet and O-ring; coat
the O-ring lightly with clean, thin oil.
13. If the fuel pressure regulator was removed, re-
place the O-ring with a new one and coat it lightly with
clean, thin oil. Insert the regulator straight into the rail,
then check that it can be rotated freely. If it does not ro-
tate smoothly, remove it and inspect the O-ring for de-
formation or jamming. When properly installed, align
the mounting holes and tighten the retaining bolts to 7
ft. Ibs. (9 Nm). This procedure must be followed even if
the fuel rail was not removed.
14. Install the injector into the fuel rail, constantly
turning the injector left and right during installation.
When fully installed, the injector should still turn
freely in the rail. If it does not, remove the injector
and inspect the O-ring for deformation or damage.
15. Install the delivery pipe and injectors to the
engine. Make certain that each injector fits correctly
into its port and that the rubber insulators for the fuel
rail mounts are in position.
16. Install the fuel rail retaining bolts and tighten
them to 9 ff. Ibs. (12 Nm).
17. Connect the wiring harnesses to the appro-
priate injector.

5-8 FUELSYSTEM
9 ,npimr w1m.m
1: i”“L,
1: 82”w
93155gx Fig. 31 Exploded view of the fuel injectors and related components-
s.OL engines
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
6. Disconnect the fuel return hose and remove
the O-ring.
7. Disconnect the vacuum hose from the fuel
pressure regulator.
8. Detach the electrical connectors from each
injector.
9. Remove the fuel pipe connectmg the fuel
rails. Remove the injector rail retaining bolts. Make
sure the rubber mounting bushings do not get lost.
10. Lift the rail assemblies up and away from the
engine.
11. Remove the injectors from the rail by pulling
gently. Discard the lower insulator.
To install:
*Some of the vehicles may have a clip that
secures the injector to the fuel rail. Be sure
to remove or install the injector clip where
necessary.
12. Install a new grommet and O-ring to the in-
jector. Coat the O-ring with light oil.
13. Install the injector to the fuel rail.
14. Replace the seats in the intake manifold. In-
stall the fuel rails and injectors to the manifold. Make
sure the rubber bushings are in place before tighten-
ing the mounting bolts.
15. Tighten the retaining bolts to 7-9 ft. Ibs.
(W-13 Nm) Install the fuel pipe with new gasket.
16. Attach the electrical connectors to the injec-
tors
Fig. 32 Exploded view of the fuel injectors and related components-
3.5L engine
17. Connect the fuel return hose.
18. Replace the O-ring, lightly lubricate it and
connect the high pressure fuel line.
19. Usmg new gaskets, install the intake plenum
and all related items. Refer to Section 3.
20. Fill the cooling system.
21. Connect the negative battery cable and check
the entire system for proper operation and leaks.
The easiest way to test the operation of the fuel in-
jectors is to listen for a clicking sound coming from
the injectors while the engine IS running. This is ac-
complished using a mechanic’s stethoscope, or a
long screwdriver. Place the end of the stethoscope or
the screwdriver (tip end, not handle) onto the body of
the injector. Place the ear pieces of the stethoscope
in your ears, or if using a screwdriver, place your ear
on top of the handle. An audible chcking noise
should be heard; this is the solenoid operating. If the
injector makes this noise, the injector driver circuit
and computer are operating as designed. Continue
testing all the injectors this way.
Be extremely careful while working on an op-
erating engine, make sure you have no dan-
gling jewelry, extremely loose clothes,
power tool cords or other items that might
get caught in a moving part of the ermine.
All Injectors Clicking
If all the injectors are clicking, but you have de-
termined that the fuel system is the cause of your
driveability problem, continue diagnostics. Make
sure that you have checked fuel pump pressure as
outlined earlier in this section. An easy way to de-
termine a weak or unproductive cylinder is a cylin-
der drop test. This is accomplished by removing
one spark plug wire at a time, and seeing which cylinder causes the least difference in the idle.
The one that causes the least change is the weak
cylinder.
If the injectors were all clicking and the ignition
system is functioning properly, remove the injector of
the suspect cylinder and bench test it. This is accom-
plished by checking for a spray pattern from the in-
jector itself Install a fuel supply line to the injector
(or rail if the injector is left attached to the rail) and
momentarily apply 12 volts DC and a ground to the
injector itself; a visible fuel spray should appear. If no
spray is achieved, replace the injector and check the
running condition of the engine.
One or More Injectors Are Not Clicking
6 See Figures 33, 34, 35, and 36
If one or more injectors are found to be not operat-
ing, testing the injector driver circuit and computer
can be accomplished using a “noid” light. First, with
the engine not running and the ignition key in the
OFF position, remove the connector from the injector
you plan to test, then plug the “noid” light tool into
the injector connector. Start the engine and the
“noid” light should flash, signaling that the injector
driver circuit is working. If the “noid” light flashes,
but the injector does not click when plugged in, test
the injectors resistance. Resistance should be be-
tween:
l All non-turbo engines: 13-16 ohms at 68°F
(20°C)
l Turbocharged engines: 2-3 ohms at 68 “F
(20°C)
If the “noid” light does not flash, the injector dri-
ver circuit is faulty. Disconnect the negative battery
cable. Unplug the “noid” light from the injector con-
nector and also unplug the PCM. Check the harness
between the appropriate pins on the harness side of
the PCM connector and the injector connector. Re-
sistance should be less than 5.0 ohms; if not, repair
the circuit. If resistance
IS within specifications, the
injector driver inside the PCM is faulty and replace-
ment of the PCM will be necessary.

FUELSYSTEM 5-9
p See Figures 37, 38, 39, 49, and 41
REMOVAL& INSTALLATION
1. Properly relieve the fuel system pressure as
outlined earlier in this section.
2. Remove the vacuum hose from the fuel pres-
sure regulator.
3. Disconnect the fuel return hose from the
pressure regulator.
Fig. 33 Unplug the fuel injector connector
, Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not apow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
I ,“~“*I.“. ..-.. * . ..” ._“. .-... To install:
I
Fig. 36 If the correct “noid” light flashes
while the engine is running, the injector dri-
ver circuit inside the PCM is working 5. Replace the O-ring on fuel pressure regulator
with a new one and coat it lightly with clean, thin oil.
6. Insert the regulator straight into the rail, then
chl . . . . . * * . . , .
xk mat n can oe rorarea rreery. 4. Remove the fuel regulator retainer bolts or re-
move the retaining snapring, then remove the fuel rrwkdnr frnm the fl~el rail
91055pu2 Fig. 35 Plug the correct “noid” light directly
into the iniector harness connector
I I I , r,
If it does not rotate smoothly, remove it
and inspect the O-ring for deformation or
damage.
7. When properly installed, align the mounting
holes. If equipped, install and tighten the retaining
bolts to 8 ft. Ibs. (11 Nm). If equipped, install the reg-
ulator retaining snapring.
8. Connect the fuel return hose to the pressure
regulator.
9. Install the vacuum hose to the fuel pressure
regulator.
10. Connect the negative battery cable and pres-
surize the fuel system. Inspect for leaks.
1 ret;rnline ~ . . g315sp10 1 1 ~~~.~~~s~~~~~u~s,“p”“““’ the hose? 1 Fig 37 Remove the hose clamp on the fuel
Fig. 39 Remove the vacuum hose from the
pressure regulator Fig. 40 Remove the regulator-to-fuel rail re-
taining bolts, then remove the pressure reg-
ulator from the fuel rail

5-10 FUELSYSTEM
1. _
Fuel tank pressure
-
relef vdive

REMOVAL &INSTALLATION
p See Figures 42 and 43
1. Raise and safely support the vehicle securely
on jackstands.
2. Remove the hoses and remove the pressure re-
lief valve.
3. The installation is the reverse of removal.
c, Always install the pressure relief valve
with the arrow pointing toward the EVAP can-
ister side, not the fuel tank 1 mame shown, others similar g3155g” Fig 42 Pressure relief valve location-llia
I I
Evaporatwe emlsslon
canister side
Tank side
+k
93155gt7 Fig. 43 Always install the pressure relief
valve with the arrow pointing toward the
EVAP canister side, not the fuel tank
REMOVAL&INSTALLATION
p See Figures 44 thru 58
1. Properly relieve the fuel system pressure us-
ing proper procedures.
2. Disconnect the negative battery cable.
3. Raise the vehicle and support safelv.
4. Drain the fuel from the fuel tank into an
ap- proved container.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
5. On Diamante models:
a. Remove the left rear wheel well liner.
b Disconnect the center exhaust system from
the main muffler. Disconnect the rear exhaust
hangers, lower the exhaust and secure aside.
c. On models equipped with 4-wheel steering,
remove the mounting bolts and lower the rear
steering gear.
6. Disconnect the return hose, high pressure
hose and vapor hoses from the fuel pump.
7. Detach the electrical connectors at the
pump/sending unit.
8. Disconnect the filler and vent hoses.
s
9. Place a suitable jack under the center of the
fuel tank and apply a slight upward pressure. Remove
the fuel tank strap retaining nuts.
10. Lower the tank slightly and detach any re-
maining electrical or hose connectors at the fuel tank.
11. Remove the fuel tank from the vehicle.
To install: 12. If replacing the tank, transfer any necessary
components to the new tank including any heat
shields, hoses, valves, and the fuel pump.
13. Install the fuel tank onto the jack. Rarse the
tank in position under the vehicle. Leave enough
Tg. 44 Fuel tank and related components exploded view-1990-92
mirage
clearance to attach the electrical and hose connec-
tions to the top of the fuel pump.
14. Attach all connectrons to the top of the tank.
15. Raise the tank completely and position the re-
tainer straps around the fuel tank. Install new fuel
tank self-locking nuts and tighten the nuts.
16. Connect the return hose and high pressure
hoses.
17. Install the vapor hose and the filler hose. In-
stall the filler hose retainer screws to the fender, if re-
moved.
18. On Diamante models:
a. If equipped with 4-wheel steering, install
the power cylinder unit and tighten the mounting
bolts to 31 ft. Ibs. (43 Nm).
b. Connect the exhaust pipe and secure the
rear hangers.
c. Install the left rear wheel well liner, if re-
moved.
19. Lower the vehicle and pour the drained fuel
into the gas tank.
20. Connect the negative battery cable. Check the
fuel pump for proper pressure and inspect the entire
system for leaks.
:ig. 45
vlirage Fuel tank and related 93155(12E components exploded view-1993-96

FUELSYSTEM 5-11
93155gZi Fig. 46 Fuel tank and related components exploded view-1997-98
Mirage
Vapor hose
Filler
hose
Fig. 48 Connection of the vapor and filler hoses-1990-93 FWD Galanl Qt. 49 Fuel tank and related components-1990-93 FWD Galant
1990-92 Mirage
p See Figure 44
REMOVAL &INSTALLATION
Fuel injection systems remain under pres-
sure after the engine has been turned OFF.
Properly relieve fuel pressure before discon-
necting any fuel lines. Failure to do so may
result in fire or personal iniury.
*Cover all fuel hose connections with a
shop towel, prior to disconnecting, to prevent
splash of fuel that could be caused by resid-
ual pressure remaining in the fuel line. Fig. 47 Fuel tank and related components exploded view-1999-00
1996 moclab>
1. Properly relieve the fuel system pressure us-
ing proper procedures. Disconnect the negative bat-
tery cable
2. Raise the vehicle and support safely.
3.
Dram the fuel from the fuel tank Into an ap-
proved container.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin- guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
4. Lower the tank slightly and detach any re-
maining electrical or hose connectors at the fuel tank.
5. Remove the fuel tank from the vehicle as de-
scribed In this section.
6 Remove the five nuts securing the fuel pump
to the fuel tank and remove the pump assembly.
To install:
7. Install fuel pump into fuel tank, with new
packing gasket, and tighten mounting nuts.
8. Install the fuel tank into the vehrcle. Refer to
the procedure in this section.

5-12 FUELSYSTEM
Fig. 50 Fuel tank and related components-1990-93 AWD Galant
:ig. 52 Fuel tank and related components-1994-96 Galant with Cal-
fornia emissions
9. Lower the vehicle and pour the drained fuel
into the gas tank. 1. Relieve the fuel system pressure using proper
procedure. ventilated area. Do not allow fuel spray or
10. Connect the negative battery cable.
11. Check the fuel pump for proper pressure and 2. Disconnect negative battery cable. vapors to come in contact with a spark or
J
inspect the entire system for leaks, 3. Raise and safely support the vehicle. open flame. Keep a dry chemical fire extin-
4. Drain the fuel from the fuel tank Into an ap- guisher near the work area. Always keep fuel
in a container specifically designed for fuel
1990-93 Galant
FRONT WHEEL DRIVE (FWD)
e See Figures 59, 60, and 61
proved gasoline container. storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
5. Remove the electrical connectors at the fuel
pump. Make sure there is enough slack in the electri-

FUELSYSTiM 5-13
1. BODY HARNESS CONNECTION
2 HOSE CONNECTION
3 PURGE HOSE
4 VAPOR HOSE
5 VENT HOSE
6 FllLER HOSE
7 PIPE ASSEMBLY
8. BAND ASSEMBLY
9 FUEL TANK ASSEMBLY
10. DIFFERENTIAL PRESSURE
SENSOR
11 FUEL HARNESS
12 HIGH-PRESSURE FUEL HOSE 1; ;;JL RETURN HOSE
15 FUEL PUMP MODULE
16 FILLER NECK
17 FUEL CAP
IS REINFORCEMENT
19 PACKING
20 VAPOR HOSE
21 SEPARATOR ASSEMBLY
22 VAPOR HOSE
23 FUEL CHECK VALVE ASSEMBLY
24 FUEL FILLER NECK ASSEMBLY
Fig. 54 Fuel tank and related components-1999-00 Galant
:ia. 55 Fuel tank and related components-1992-96 Diamante
11. Align the 3 projections on packing with the
holes on the fuel pump and the nipples on the pump
facing the same direction as before removal.
12. Install the holdrng bolt through the bottom of
the tank. Make sure the gasket on the bolt is replaced
and is not pinched during installation. Torque to 10
ft. Ibs. (14 Nm).
1 PatkIng brake cable COnneCtlo” 11
2 Fuel tank “.qm hose
12 Fuel fllk, neck
3 “apot hose 13 Fuel filler assembly
4 Pressure hose 14
5 Vapor hose COnneCflOn Fuel p,pe
6 Fuel pump am gauge assembly
7 Vapor hose
8 Valve assembly
9 Fuel mer cap
10 FllkY hose
:ig. 56 Fuel tank and related components-1997-00 Diamante 93155g15
cal harness of the fuel gauge unit to allow for the fuel
pling. Lower the lateral rod and suspend from the
tank to be lowered slightly. If not, label and discon-
axle beam using wire.
nect the electrical harness at the fuel gauge unit.
6. Detach the high pressure fuel line connector 9. Remove the six retaining bolts and gasket
from the base of the tank.
at the pump.
10. Remove the fuel pump assembly.
7. Loosen self-lockinq nuts on tank suooort
To install: straps to the end of the stud bolts.
8 Remove the right side lateral rod attaching
bolt and drsconnect the arm from the right body cou- *If the packing material is damaged or de-
formed, replace it with new packing.
7923PG79 :ig. 57 Proper method of supporting real
rxhaust system-Diamante 3.01 engine