Removal and installation of the fuel pump / fuel flow sensor

Warning! Remember that gasoline is a highly flammable liquid! Observe all applicable fire safety precautions when working on power system components. Do not smoke! Do not approach the place of work with an open flame or carrying an unprotected lampshade! Do not service the system in rooms equipped with natural gas-fired heaters equipped with a pilot flame (such as water heaters and clothes dryers). Do not forget that gasoline is classified as a carcinogen, i.e., substances that contribute to the development of cancer! Try to avoid getting fuel on open areas of the body, use rubber protective gloves, in case of accidental unexpected contact with fuel, thoroughly wash your hands with warm water and soap. Clean up spilled fuel immediately and do not store fuel-soaked rags near open flames. Remember that the fuel injection system of models equipped with fuel injection is constantly under pressure. Relieve any residual pressure in the system before attempting to disconnect fuel lines. Wear safety goggles when servicing power system components. Keep a class B fire extinguisher handy at all times!

Mirage models 1990÷1992 issue

Removing

1. Installation details of the fuel pump/fuel flow sensor assembly on Mirage models 1990÷1992. issue shown in the illustration.

2. Relieve pressure in the supply system (see Section Depressurizing the supply system).

3. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

4. Drain the remaining fuel from the tank into a suitable container.

5. Slightly lower the fuel tank assembly and disconnect the electrical wiring and communication lines brought to its upper part.

6. Remove the fuel tank from the car (see Section Removal and installation of the fuel tank).

7. Give five fixing nuts and take assembly of the fuel pump/fuel flow sensor from a tank.

Installation

1. Install the fuel pump / flow sensor assembly in its original place - do not forget to replace the gasket. Screw on and tighten the fixing nuts.

2. Install the fuel tank assembly on the vehicle (see Section Removal and installation of the fuel tank).

3. Lower the vehicle to the ground and pour the drained fuel back into the gas tank.

4. Connect the negative cable to the battery.

5. Check the pressure characteristic of the fuel pump (see Section Check of serviceability of functioning of the fuel pump, measurement of pressure of fuel). Inspect the power system path for signs of leak development.

Front wheel drive models (FWD) Galant 1990÷1993 issue

Removing

1. Relieve the pressure in the supply system (see Section Depressurizing the supply system).

2. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

3. Drain the remaining fuel from the tank into a suitable container.

4. Disconnect the electrical wiring connected to the fuel pump assembly, make sure that there is enough slack in the fuel flow sensor wiring harness to lower the tank. If necessary, also disconnect the sensor wiring, having previously marked the harness.

5. Disconnect the pressure line from the pump.



6. Loosen the self-locking nuts securing the tank mounting brackets

7. Turn out bolts of fastening of the right cross-bar and disconnect the lever from an articulation of a body element. Lower the cross bar and tie it with wire to the rear axle assembly.



8. Turn out six fixing bolts and remove the sealing lining installed in the basis of a tank.


9. Remove the fuel pump assembly.

Installation

1. Align the gasket-mounted three drive pins with the corresponding holes in the pump assembly. Make sure that the nipples are turned in the same direction as before removing the pump.

2. Pass the mounting bolt through the hole in the bottom of the tank (don't forget to replace the gasket) and tighten it to the required torque (14 Nm).

3. Install the right cross bar, screw the mounting bolt into the corresponding body joint and loosely tighten it.

4. Tighten the self-locking nuts of the tank mounting bands until the tank is firmly seated on the vehicle. Tighten the nuts to the required torque (31 Nm).

5. Connect the pressure hose and tighten its fitting connector with the required force (40 Nm).

6. Connect the electrical wiring to the fuel pump/fuel flow sensor assembly.

7. Lower the vehicle to the ground and finally tighten the cross bar bolt to the required torque (80÷100 Nm).

8. Pour the drained fuel into the tank.

9. Connect the negative cable to the battery.

10. Check the proper functioning of the power system, inspect its path for signs of leakage development.

All-wheel drive models (AWD) Galant 1990÷1993 issue

Removing

1. Relieve the pressure in the supply system (see Section Depressurizing the supply system).

2. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

3. The fuel pump is placed inside the tank. Remove the access cover installed in the rear floor panel of the vehicle.

4. Drain the remaining fuel in the tank into a suitable container.

5. Disconnect the electrical wiring from the pump assembly.

6. If necessary, remove the two-way fuel level control valve in the tank.

7. Disconnect the pressure line.



8. Remove the six mounting bolts and remove the fuel pump/fuel flow sensor assembly from the tank.

9. Align the gasket-mounted three drive pins with the corresponding holes in the pump assembly. Make sure that the nipples are turned in the same direction as before removing the pump. Install the holders and tighten them to the required torque (3 Nm).

10. Connect the pressure hose and tighten its fitting connector with the required force (40 Nm).

11. Replace the 2-way restrictor valve and connect the electrical wiring to the pump assembly.

12. Pour the drained fuel into the tank.

13. Connect the negative cable to the battery.

14. Check the proper functioning of the power system, inspect its path for signs of leakage development.



15. Place the 3M ATD No. 8625 sealing element on the floor panel, then install and secure the service cover.

Galant models 1994÷1998 issue, Mirage 1993÷2000 issue and Diamante

Removing

1. Relieve the pressure in the supply system (see Section Depressurizing the supply system).

2. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

3. Remove the rear seat cushion (see chapter Body).

4. Remove the service cover to access the submersible fuel pump/fuel flow sensor assembly.




5. Disconnect the electrical wiring from the pump assembly.

6. Disconnect return hose and pressure line.



7. Give fixing nuts and remove assembly.

Installation

1. Place a new gasket on the tank seat.

2. Fill the fuel pump/fuel flow sensor assembly into the tank. Screw in the mounting bolts and tighten them with the required force (2.5 Nm).

Note. When introducing the pump assembly into the tank, the measuring float of the fuel flow sensor should be bent to the left.

3. Connect pressure line and fuel return hose to assembly.

4. Connect electrical wiring.

5. Connect the negative cable to the battery.

6. Check the pressure characteristic of the fuel pump (see Section Check of serviceability of functioning of the fuel pump, measurement of pressure of fuel). Inspect the elements of the power system path for signs of leak development.

7. Seal the service access cover to the pump. Install the rear seat cushion (see chapter Body).

1999 and 2000 Galant models issue

Removing

1. Relieve the pressure in the supply system (see Section Depressurizing the supply system).

2. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

3. Remove the rear seat cushion (see chapter Body).

4. Remove the service cover to access the submersible fuel pump/fuel flow sensor assembly.

5. Disconnect the electrical wiring from the pump assembly.

6. Disconnect return hose and pressure line.



7. Using the special tool type MB991480, release the retaining cap and remove the fuel pump/fuel flow sensor assembly.

Installation

1. Place a new gasket on the tank seat.

2. Fill the fuel pump/fuel flow sensor assembly into the tank, - make sure that the landing marks applied to the assembly and the floor panel are aligned correctly.

3. Using the special tool MB991480, tighten the fixing cap.

4. Connect pressure line and fuel return hose to assembly.

5. Connect electrical wiring.

6. Connect the negative cable to the battery.

7. Check the pressure characteristic of the fuel pump (see Section Check of serviceability of functioning of the fuel pump, measurement of pressure of fuel). Inspect the elements of the power system path for signs of leak development.

8. Seal the service access cover to the pump.

9. Reinstall the rear seat cushion (see chapter Body).