Removal (Outlander)
WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 Mitsubishi Outlander, 2003 Mitsubishi Montero Sport, 2003 Mitsubishi Montero, 2003 Mitsubishi Lancer, and 2003 Mitsubishi Galant. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
On 4WD equipped vehicles, be careful not to bend joint portion when removing or installing drive shaft. This will damage joint boot.
CAUTION:
DO NOT lower fuel tank assembly too much to prevent damaging fuel leveling hose and fuel vapor hose "A".
CAUTION:
Support fuel tank assembly securely so that it does not fall off from transaxle jack.
- Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Drain fuel tank into suitable container. Raise and support vehicle.
- Remove center exhaust pipe. See Figure. On vehicles equipped with 2WD, go to next step. On vehicles equipped with 4WD, remove insulator heat protector. See Fig 1. Remove insulator and spacer. Make mating marks on differential companion flange and drive shaft assembly. See Fig 2. Insert a rag so as to avoid boot damage. See Fig 3. Remove drive shaft assembly in a straight and level manner. Remove rear differential support member bolts. See Fig 4.
- On all vehicles, remove protector. See Fig 5. Remove left side parking brake cable clamp. Disconnect main pipe side high-pressure fuel hose. Disconnect return pipe side fuel return hose. Raise and support fuel tank assembly with a transaxle jack. See Fig 6. Remove fuel tank installation nuts and bolts. After lowering fuel tank assembly approximately 1.18" (30 mm), disconnect fuel filler hose, fuel leveling hose and fuel vapor hose "A" from fuel filler neck. See Fig 7.
- Lower fuel tank assembly further and ensure adequate clearance in order to disconnect harness connectors. See Fig 8. Disconnect harness connector. Open 5 harness clips and remove fuel wiring harness from fuel tank. See Fig 9 and Fig 10 . Disconnect fuel wiring harness. Remove fuel tank assembly.