fuel MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

MPI -Injector13A-141
INJECTOR
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DFuel Discharge Prevention (Refer to P.13A-125.)
DStrut Tower Bar Removal and Installation
(Refer to GROUP 42.)DAir Hose E, Air By-pass Hose, Air Pipe C Removal
and Installation (Refer to GROUP 15 - Intercooler.)
DFuel Leakage Check
21
3
13 5
6
7
8 9 1011 12
4
8.9±1.9N·m
8.9±1.9N·m 5.0±1.0N·m
Apply engine oil to all
moving parts during
installation.
14 15
16 12
6
5.0±1.0N·m
Removal steps
1. Control harness connector
2. Accelerator cable assembly
connection (Throttle body side)
3. Injector harness connector
"AA4. High-pressure fuel hose connection
5. O-ring
6. Fuel return hose connection
7. Vacuum sensor connector
"AA8. Fuel pressure regulator9. O-ring
10. Fuel return pipe
AA"11. Delivery pipe
12. Insulator
13. Insulator
AA""AA14. Injector
15. Grommet
16. O-ring

MPI -Injector13A-142
REMOVAL SERVICE POINT
AA"DELIVERY PIPE/INJECTOR REMOVAL
Remove the delivery pipe (with the injectors attached to it).
Caution
Care must be taken, when removing the delivery pipe,
not to drop the injector.
INSTALLATION SERVICE POINT
"AAINJECTOR/FUEL PRESSURE REGULATOR
/HIGH-PRESSURE FUEL HOSE INSTALLATION
1. Apply a drop of new engine oil to the O-ring.
Caution
Be sure not to let engine oil enter the delivery pipe.
2. While turning the injector, high-pressure fuel hose and
fuel pressure regulator to the right and left, install the
delivery pipe, while being careful not to damage the O-ring.
After installing, check that the hose turns smoothly.
3. If it does not turn smoothly, the O-ring may be trapped,
remove the injector, high-pressure fuel hose or fuel
pressure regulator and then re-insert it into the delivery
pipe and check once again.
4. Tighten the high-pressure fuel hose and fuel pressure
regulator to the specified torque.
Tightening torque:
5.0±1.0 N·m (High-pressure fuel hose)
8.9±1.9 N·m (Fuel pressure regulator)

MPI -Engine Control Resistor, Relay13A-146
ENGINE CONTROL RESISTOR, RELAY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DHarness Connector Connection
213
4
5.0¶1.0 N·m
5.0±1.0N·m5.0±1.0N·m
2.5±0.5N·m
5.0±1.0N·m
AYC relay
4 2
5.0±1.0N·m
5.0±1.0N·mAYC relay5.0±1.0N·m5.0±1.0N·m
2.5±0.5N·m13


Removal steps
DAYC relay
1. Fuel pump relay
2. Injector resistor
3. Bracket
4. Fuel pump resistor

13B-1
FUEL SUPPLY
CONTENTS
GENERAL INFORMATION 2..................
ON-VEHICLE SERVICE 2.....................FUEL TANK 3...............................

FUEL SUPPLY - General Information/On-vehicle Service13B-2
GENERAL INFORMATION
DThe steel fuel tank is located under the floor of the rear seats to provide increased safety and increase
the amount of luggage compartment space.
DThe fuel tank has been equipped with a valve assembly which incorporates a fuel cut-off valve to
prevent fuel from leaking out in the event of a collision for adjusting the pressure inside the fuel
tank.
DThe fuel pump module contains a fuel pump, fuel filter, and fuel pressure regulator.
ON-VEHICLE SERVICE
FUEL PUMP AND GAUGE ASSEMBLY (FUEL
PUMP)
1. FUEL PUMP OPERATION CHECK
Refer to GROUP 13A - On-vehicle service
2. FUEL PUMP REPLACEMENT
(1) Remove the rear seat cushion assembly.
(Refer to GROUP 52A.)
(2) Remove the service hole cover.
(3) Disconnect the harness connector, high-pressure fuel
tube, suction hose and return hose.
(4) Unscrew the mounting nuts to remove the fuel pump
and gauge assembly.
(5) Replace the fuel pump. (Refer to P.13B-7.)
(6) Install the fuel pump and gauge assembly. Tighten
the mounting nuts to the specified torque.
Specified torque: 2.5± 0.5 N·m
(7) Connect the harness connector, high-pressure fuel
tube, suction hose, and return hose.
Caution
1) Snap the high-pressure fuel hose or suction
hose one-touch joint into place, then pull back
slightly on the hose to assure it is securely
fitted. However, the connection should have
a play of approx. 3 mm.
2) Insert the return hose for 20 - 30 mm for
connection.
(8) Install the service hole cover.
(9) Install the rear seat cushion assembly.
(Refer to GROUP 52A.)
Harness
connectorHigh-pressurefuel tube
Suction hose
Return hose

3mm
Corresponding
sideHigh-pressure fuel tube

FUEL SUPPLY - On-vehicle Service/Fuel tank13B-3
FUEL PUMP AND GAUGE ASSEMBLY, PIPE
AND GAUGE ASSEMBLY (FUEL GAUGE UNIT)
1. Remove the rear seat cushion assembly.
(Refer to GROUP 52A.)
2. Remove the service hole cover.
3. Disconnect the harness connector, high-pressure fuel
tube, suction hose, and return hose.
4. Unscrew the mounting nuts to remove the fuel pump
and gauge assembly or pipe and gauge assembly.
5. Fuel gauge unit check. (Refer to GROUP 54 -
Combination Meter.)
NOTE
If the inspection shows that the basic resistance and
the height of float are out of the standard value, replace
the gauge unit.
(Refer to P.13B-8.)
6. Install the fuel pump and gauge assembly or pipe and
gauge assembly. Tighten the mounting nuts to the
specified torque.
Specified torque: 2.5± 0.5 N·m
7. Connect the harness connector, high-pressure fuel tube,
suction hose, and return hose.
Caution
(1) Snap the high-pressure fuel hose or suction hose
one-touch joint into place, then pull back slightly
on the hose to assure it is securely fitted. However,
the connection should have a play of approx. 3
mm.
(2) Insert the return hose for 20 - 30 mm for
connection.
8. Install the rear seat cushion assembly.
(Refer to GROUP 52A.)
FUEL TANK
REMOVAL AND INSTALLATION
Pre-removal Operation
DDraining Fuel
DFuel Pump Connector Disconnection
(How To Reduce Fuel Pressure)
(Refer to GROUP 13A - On-vehicle Service.)
DCenter Exhaust Pipe Removal
(Refer to GROUP 15.)Post-installation Operation
DCenter Exhaust Pipe Removal
(Refer to GROUP 15.)
DRefilling Fuel
DChecking for Fuel Leaks
High-pressurefuel tubeHarness
connector
Suction hose
Return hose
Suction hose
Harness connector

FUEL SUPPLY - Fuel Tank13B-4

12
10
6 21
1
2
4
7 8
915 18
23 20
13 314
22
24 1119
5
16 175
2.5±0.5 N·m
2.5±0.5 N·m
26±4 N·m
22±4 N·m
Removal steps
1. Filler neck pipe, Filler neck vapour
pipe connection
2. Vapour pipe connection
3. Main pipe connection
4. Return pipe connection
DParking brake cable clamp (LH)
connection (Refer to GROUP 36.)
DRear wheel speed sensor (RH)
connection
(Refer to GROUP 35 - Wheel speed
sensor.)
DRear wheel speed sensor harness
connector connection
(Refer to GROUP 35 - Wheel speed
sensor.)
AA"5. Harness connector connection
AA"6. Fuel tank assembly
7. Fuel tank protector"AA8. Suction hose
"AA9. High-pressure fuel hose
10. Fuel tank pipe assembly
"AA11. High-pressure fuel hose
"BA12. Fuel tank return hose
13. Return hose
14. Fuel tank vapour hose
15. Check valve
16. Vapour hose
17. Pipe and gauge assembly
18. Plate
19. Fuel pump and gauge assembly
20. Parking
21. Fuel cut off valve assembly
22. Parking
23. Filler neck hose
24. Filler neck vapour hose

FUEL SUPPLY - Fuel Tank13B-5

303128
25 29
2627
24±4 N·m
Removal steps
25. Filler neck protector
26. Filler neck hose connection
27. Filler neck vapour hose connection
28. Fuel filler cap29. Fuel filler neck assembly
30. Fuel shut-off valve
31. Parking
REMOVAL SERVICE POINT
AA"HARNESS CONNECTOR CONNECTION/FUEL
TANK ASSEMBLY DISCONNECTION
1. Remove the differential support member and tilt the
differential carrier.
(Refer to GROUP 27B.)
2. Hold the fuel tank with a transmission jack and remove
the nut connected to the fuel tank.
3. Tilt the fuel tank to allow access with a hand and disconnect
the harness connector.
4. Remove the fuel tank in the tilting direction to avoid contact
with the differential carrier.Fuel tankFloor
Differntial carrierRemoval
directionTilt

FUEL SUPPLY - Fuel Tank13B-6
INSTALLATION SERVICE POINT
"AAHIGH-PRESSURE FUEL HOSE/SUCTION HOSE
INSTALLATION
Caution
Snap the high-pressure fuel hose or suction hose
one-touch joint into place, then pull back slightly on the
hose to assure it is securely fitted. However, the
connection should have a play of approx. 3 mm.
"BAFUEL TANK RETURN HOSE INSTALLATION
Caution
Insert the return hose for 20 - 30 mm for connection.
3mm
Corresponding
sideHigh-pressure fuel tube

FUEL SUPPLY - Fuel Tank13B-7
DISASSEMBLY AND REASSEMBLY

1
2
34 567
9
8101112 13
Removal steps
1. Fuel gauge unit
2. Gauge harness
3. Bracket
4. Fuel pump cushion
5. Fuel pump
6. Spacer
"AA7. Grommet8. Assist pump
9. Fuel suction hose
10. Fuel return hose
11. Cap
"AA12. O-ring
13. Fuel filter assembly