Removal and installation the fuel tank (Mitsubishi Galant 6)

The article is reprinted from a web resource [MITSUBISHIMAN.ru]

Warning! Remember that gasoline is highly flammable! When working with fuel system components, observe all accepted fire safety measures. Do not smoke! Do not approach the work area with an open flame or unprotected portable appliance! Do not service the system in rooms equipped with natural gas heating devices equipped with a pilot flame (such as water heaters and clothes dryers). Do not forget that gasoline is a carcinogen, i.e., a substance that promotes the development of cancer! Try to avoid fuel coming into contact with exposed areas of the body, use rubber protective gloves, and in case of accidental contact with fuel, wash your hands thoroughly with warm water and soap. Collect spilled fuel immediately and do not store rags soaked in fuel near open flames. Remember that the fuel system of models equipped with fuel injection is constantly under pressure. Before disconnecting fuel lines, relieve residual pressure in the system. Wear safety glasses when servicing fuel system components. Always keep a Class B fire extinguisher on hand!

Removal

1. The fuel tank installation details are shown in the illustrations.



2. Release the pressure in the fuel system (see Section Relieving pressure in the fuel system).

3. Disconnect the negative cable from the battery.

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

4. Jack up the car and place it on supports.

5. Drain the remaining fuel from the gas tank into a suitable receiving container.

6. On Diamante models:

• a) Remove the left rear wheel arch protection liner;
• b) Disconnect the center section of the exhaust system from the main muffler. Remove the rear section of the exhaust system from its hangers and lower it, move it to the side and tie it up;
• c) On models equipped with rear wheel steering, remove the mounting bolts and rear steering gear assembly.

7. Disconnect the pressure and return hoses from the fuel pump assembly. Also disconnect the fuel vapor discharge hoses.

8. Disconnect the electrical wiring from the fuel pump/fuel flow metering unit assembly.

9. Disconnect the filler neck and ventilation hoses from the tank.

10. Place a suitable jack under the center of the tank, support the assembly with it and loosen the nuts securing the mounting brackets (bands).

11. Lower the tank slightly and disconnect the remaining communication lines (electrical wiring, hoses, tubes, etc.) from it.

12. Remove the tank from under the vehicle.

Installation

1. If the tank is to be replaced, transfer the various add-on components from the tank to the replacement assembly, including heat shields, connecting hoses, valves, and the fuel pump/flow sensor assembly.

2. Secure the new tank to the jack head and slide it into place under the vehicle, leaving enough clearance to connect the service lines to the top of the pump assembly.

3. Connect the appropriate communication lines to the top of the tank.

4. Raise the jack, finally bringing the tank to its standard position. Install the mounting straps and secure them with new self-locking nuts.

5. Restore the original connection of the pressure and return lines.

6. Connect the filler neck hose and vent line. Use the special screws to secure the filler neck assembly to the vehicle fender.

7. On Diamante models:

• a) If equipped, install the rear wheel power steering, screw in the mounting bolts and tighten them to the required torque (43 Nm);
• b) Install and secure the rear section of the exhaust system to the hangers;
• c) If removed, install the left rear wheel arch protection liner.

8. Lower the vehicle to the ground and pour the drained fuel back into the tank. Check the fuel pump for proper operation (see below), inspect the fuel system for signs of leaks.