1900 MITSUBISHI DIAMANTE Repair Manual

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Page 185 of 408

MITSUBISHI DIAMANTE 1900 Repair Manual 4-42 DRIVEABILITYAND EMISSIONS CONTROLS
Emission control system vacuum hose
routing-1994-96 2.4L engine, Federal
emissions
Emission control system vacuum hose
routing-1994-96 2.4L engine, Califor

Page 186 of 408

MITSUBISHI DIAMANTE 1900 Repair Manual DRIVEABILITYAND EMISSIONSCONTROL-S 4-43
L. Light blue
R. Red
B Black Fuel pressure
regulator
. Vehicle front
93154~33
I Fuel pressure
regulator
Vehicle front
93154V34
Emission control syste

Page 187 of 408

MITSUBISHI DIAMANTE 1900 Repair Manual 4-44 DRIVEABILITYAND EMISSIONS CONTROLS
Emission control system vacuum hose
pouting-1993-96 3.OL engines (SOHC and
DOHC) w/traction control, California emis-
rions Emission control system vacuum h

Page 188 of 408

MITSUBISHI DIAMANTE 1900 Repair Manual BASIC FUEL SYSTEM DIAGNOSIS 5-2
FUEL LINES AND FllllNGS 5-2
FUEL LINE FITTINGS 5-2
REMOVAL &INSTALLATION 5-2
MULTI-POINT FUEL INJECTION
SYSTEM (MPI) 5-3
GENERALINFORMATION 5-3
FUELSYSTEM SERVIC

Page 189 of 408

MITSUBISHI DIAMANTE 1900 Repair Manual I
5-2, FUELSYSTEM
When there is a problem starting or driving a vehi-
“is there fuel? will often lead to solving most basic
cle, two of the most important checks involve the ig- problems. For ig

I
5-2, FUELSYSTEM
When there is a problem starting or driving a vehi-
“is there fuel? will often lead to solving most basic
cle, two of the most important checks involve the ig- problems. For ignition system diagnosis and testing,
nition and the fuel systems. The questions most me-
please refer to the information on engine electrical
chanics attempt to answer first, “is there spark?” and
components and ignition systems found earlier in this manual. If the ignition system checks out (there
is spark), then you must determine if the fuel system
is operating properly (is there fuel?).
REMOVAL&INSTALLATION
# See Figures 1 thru 7
The fuel lines used on all models covered by this
manual are quite straight forward. Typically the fit-
tings are either rubber hoses connecting to steel lines
with clamps, or steel lines connecting to steel lines
using retaining bolts or flare fittings. Several fittings
are unique such as the banjo-bolt fitting on the fuel
feed line from the fuel filter.
ventitateu area. Do not allow fuel spray or
vapors to come in contact with a spark or
ooen flame. Keen a drv chemical fire extin- Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
___ _ . . . _
guisher near the’work &ea. Always keep fuel
in a container specifically designed for fuel
storage; also, always pmperly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion. Fig. 1 This photo of the fuel pump lines is
an example of the type of fittings found on
most models. The return line utilizes a rub-
ber hose and a hose clamp, while the feed
line utilizes a flare fitting
ren disconnect the hose from
1 the pressure regulator Fig. 2 This fitting on the fuel pressure reg-
ulator utilizes a rubber hose and a hose
clamp. Remove the hose clamp . . .
93153p45 Fig. 4 The fuel feed line-to-fuel rail fitting
is held by retaining bolts. Unfasten the
bolts . . .
Fig. 5 . . .
then remove the fuel feed line
from the fuel injector rail
I
1 Fig. 6 The fitting on the too of the fueg;?lz
I I
93155pzl Fig. 7 On the banjo-bolt type fitting, it is
ter utilizes a banjo-bolt type fitting. Re-
I I crucial that the copper washers are re-
move the bolt from the filter feed line on placed every time the fitting is removed
the top of the filter

Page 190 of 408

MITSUBISHI DIAMANTE 1900 Repair Manual FUELSYSTEM 513
l Always replace worn fuel fitting O-rings with
new. Do not substitute fuel hose or equivalent, where
I
The Multi-Point Injection (MPI) system is electroni-
rally controlled by the

FUELSYSTEM 513
l Always replace worn fuel fitting O-rings with
new. Do not substitute fuel hose or equivalent, where
I
The Multi-Point Injection (MPI) system is electroni-
rally controlled by the Engine Control Module (ECM),
based on data from various sensors. The ECM controls
the fuel flow, idle speed and ignition timing. fuel pipe is installed.
Fuel is supplied to the injectors by an electric in-
tank fuel pump and is distributed to the respective in-
jectors via the main fuel pipe. The fuel pressure ap-
plied to the injector is constant and higher than the
pressure in the intake manifold. The pressure is con-
trolled by the fuel pressure regulator. The excess fuel
is returned to the fuel tank through the fuel return pipe.
When an electric current flows in the injector, the
injector valve is fully opened to supply fuel. Since the
fuel pressure is constant, the amount of the fuel in-
jetted from the injector into the manifold is increased
or decreased in proportion to the time the electric
current flows. Based on ECU signals, the injectors in-
ject fuel to the cylinder manifold ports in firing order. Fuel injection systems remain under pres-
sure after the engine has been turned OFF.
Properly relieve fuel pressure before discon-
neeting any fuel lines. Failure to do so may
result in fire or personal injury.
1. Turn the ignition to the OFF position.
2. Loosen the fuel filler cap to release fuel tank
pressure.
I
The flow rate of the air drawn through the air
cleaner is measured by the air flow sensor. The air
enters the air intake plenum or manifold through the
throttle body. In the intake manifold, the air is mixed
with the fuel from the injectors and is drawn into the
cylinder, The air flow rate is controlled according to
the degree of the throttle valve and the servo motor
openings. The system is monitored through a num-
ber of sensors which feed information on engine con-
ditions and requirements to the ECM. The ECM cal-
culates the injection time and rate according to the
signals from the sensors,
Safety is the most important factor when perform-
ing not only fuel system maintenance but any type of
maintenance. Failure to conduct maintenance and re-
pairs in a safe manner may result in serious personal
injury or death. Maintenance and testing of the vehi-
cle’s fuel system components can be accomplished
safely and effectively by adhering to the following
rules and guidelines.
l To avoid the possibility of fire and personal in-
jury, always disconnect the negative battery cable un-
less the repair or test procedure requires that battery
voltage be applied.
l Always relieve the fuel system pressure prior to
disconnecting any fuel system component (injector,
fuel rail, pressure regulator, etc.), fitting or fuel line
connection. Exercise extreme caution whenever re- 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 va-
pors to come in contact with a spark or open
flame. Keep a dry chemical fire extinguisher
near the work area. Always keep fuel in a con-
tainer specifically designed for fuel storage;
also, always properly seal fuel containers to
avoid the possibility of fire or explosion.
3. For the Mirage, Diamante, and 1994-00
Galant, remove the rear seat cushion, then remove
the service cover and detach the fuel pump harness
connector.
4. For the 1990-93 FWD Galant, detach the fuel
pump harness connector located in the area of the
fuel tank. It may be necessary to raise the vehicle to
access the connector.
5. For the 1990-93 AWD Galant, remove the car-
pet from the trunk, locate the fuel tank wiring at the
pump access cover, then detach the wiring.
6. Start the vehicle and allow it to run until it
stalls from lack of fuel. Turn the key to the OFF posi-
tion.
7. Disconnect the negative battery cable, then at-
tach the fuel pump connector. Install the access .
cover, cushion or carpet as necessary.
8. Wrap shop towels around the fitting that is be-
ing disconnected to absorb residual fuel in the lines.
9. Place shop towels into proper safety container. Fig, 8 Detach the connector for the throttle
position (TP) sensor
93153ps5 Fig, 9 Remove the accelerator cable end
from the throttle lever
Fig. IO Remove the hose shown here from
lieving fuel system pressure to avoid exposing skin,
face and eyes to fuel spray. Please be advised that
fuel under pressure may penetrate the skin or any
part of the body that it contacts.
l Always place a shop towel or cloth around the
fitting or connection prior to loosening to absorb any
excess fuel due to spillage. Ensure that all fuel
spillage (should it occur) is quickly removed from
enginesurfaces. Ensure that all fuel soaked cloths or
towels are deposited into a suitable waste container.
l Always keep a dry chemical (Class B) fire ex-
tinguisher near the work area.
l Do not allow fuel spray or fuel vapors to come
into contact with a spark or open flame.
l Always use a backup wrench when loosening’
and tightening fuel line connection fittings. This will
prevent unnecessary stress and torsion to fuel line
piping. Always follow the proper torque specifica-
tions. REMOVAL &INSTALLATION
p See Figures 8 thru 18
1. Properly relieve the fuel system pressure as
outlined earlier in this section.
2. Drain the engine cooling system into a suit-
able container.
3. Matchmark the jocation of the adjuster bolt
on the accelerator cable mounting flange. This will
assure that the cable is installed in its original loca-
tion. Remove the throttle cable adjusting bolt and
disconnect the cable from the lever on the throttle
body. Position cable aside.

Page 191 of 408

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. Connecti

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.

Page 192 of 408

MITSUBISHI DIAMANTE 1900 Repair Manual 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 sys

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

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