Replacing Fuel Pump In '96 Galant: Step-By-Step Guide

If your 1996 Mitsubishi Galant is having trouble getting fuel, you may need to replace the fuel pump. The fuel pump is responsible for delivering gas from the fuel tank to the fuel injectors, and problems with it can cause a loss of engine power or even prevent the car from starting. Before checking the fuel pump, ensure that its fuses and relays are working. If you decide to replace the pump, you should first relieve the fuel system pressure and disconnect the negative battery cable. Take out the rear seat cushion and remove the access cover. Then, unplug the fuel pump's electrical connection and disconnect the fuel send and return hose. Remove the retaining cap for the fuel pump and install the new fuel pump, aligning the marks on the floor pan and fuel pump. Finally, complete the installation by reversing the removal procedure.

How to Replace a Fuel Pump on a 1996 Mitsubishi Galant

Disconnect the battery and relieve the fuel system pressure

Disconnecting the battery and relieving the fuel system pressure are crucial steps when replacing the fuel pump in a 1996 Mitsubishi Galant. Here is a detailed guide on how to perform these procedures safely and effectively:

Disconnecting the Battery

Before beginning any work on the fuel pump, it is essential to disconnect the battery to reduce the risk of fire. Locate the negative battery terminal, which is usually marked with a "-" symbol or a black cover. Use a socket wrench to loosen the clamp that secures the cable to the terminal. Once loose, carefully remove the cable from the battery terminal. Ensure that the cable does not touch any metal surfaces or the battery terminal to prevent accidental electrical shorts.

Relieving Fuel System Pressure

The fuel system in your Mitsubishi Galant is under pressure, and it is crucial to relieve this pressure before proceeding with any repairs or replacements. Here are the steps to safely relieve the fuel system pressure:

• Park your car on a level surface and engage the parking brake.
• Allow the engine to cool down if it has been running recently.
• Locate the fuse box, which is usually under the dashboard on the driver's side or in the engine compartment.
• Find the fuel pump fuse, which is often labeled and remove it. This will cut the power to the fuel pump.
• Start the engine and let it run until it stalls due to a lack of fuel. This will relieve the pressure in the fuel lines.
• Turn off the ignition. Do not start the engine again until the fuel pump replacement is complete, and all connections are secure.

It is important to work with extreme caution when dealing with the fuel system. Ensure proper ventilation and avoid smoking or creating any sparks near the work area. Always wear protective gear, including gloves and eye protection, when working with fuel lines or the fuel pump.

By following these steps, you will have successfully disconnected the battery and relieved the fuel system pressure in your 1996 Mitsubishi Galant, preparing you for the next steps in the fuel pump replacement process. Remember to refer to a qualified mechanic or a repair manual for further instructions on replacing the fuel pump.

Remove the rear seat cushion and the access cover

To remove the rear seat cushion and the access cover of a 1996 Mitsubishi Galant, follow these steps:

First, relieve the fuel system pressure and disconnect the negative battery cable with a socket wrench. Next, remove the rear seat cushion by pulling the seat stopper out and lifting up the lower cushion.

Now, you can remove the access cover. In the centre of the access area, there will be a square plate held on by four self-tapping screws with a cable going to its centre. Remove these four screws and pull the cable off the plate on the front corner driver's side. Pull up the plate, and you will see two harnesses that you will need to disconnect.

Once these harnesses are disconnected, you will have access to the fuel pump assembly. From here, you can proceed to unplug the fuel pump's electrical connection and disconnect the fuel send and return hose.

Disconnect the fuel pump's electrical connection and fuel hoses

Disconnecting the fuel pump's electrical connection and fuel hoses is a crucial step in replacing the fuel pump on a 1996 Mitsubishi Galant. Here is a detailed guide on how to perform this task safely and effectively:

Before beginning, ensure that you have relieved the fuel system pressure and disconnected the negative battery cable with a socket wrench. This is important to reduce the risk of fire and ensure your safety.

Now, locate the fuel pump. In most cars, the fuel pump is located inside the fuel tank and can be accessed by removing an access cover. In some cases, you may need to remove the rear seat cushion to access the fuel pump. Once you have located the fuel pump, follow these steps:

• Unplug the electrical connection: Carefully unplug the electrical connector from the fuel pump. This is usually a plug-and-socket connection, and you can simply pull it apart. Make sure to note how the connector is attached so you can properly reconnect it when installing the new fuel pump.
• Disconnect the fuel hoses: The fuel pump is connected to two fuel hoses: the fuel feed line and the fuel return line. These hoses supply fuel to the pump and return unused fuel to the tank. To disconnect the hoses, you will need to loosen the hose clamps that secure them to the fuel pump. Use a suitable tool, such as needle-nose pliers, to loosen the clamps and carefully detach the hoses. Be very careful when handling the fuel feed line, as it will be pressurized and may spray fuel if your car has not been sitting for a day or so. It is advisable to wear protective gear, such as goggles and gloves, during this step.

Once you have disconnected the electrical connection and fuel hoses, you can proceed to remove the retaining cap for the fuel pump using the appropriate tool (e.g., MB991480). After removing the retaining cap, you can lift out the fuel pump assembly.

It is important to work carefully and deliberately during this process to avoid any spills or leaks. Always be mindful of your surroundings and ensure proper ventilation when working with fuel.

After removing the old fuel pump, you can now install the new one. Simply reverse the removal procedure, ensuring that all connections are secure and proper.

Remove the retaining cap and the fuel pump

To remove the retaining cap and the fuel pump of a 1996 Mitsubishi Galant, follow these steps:

Firstly, relieve the fuel system pressure and disconnect the negative battery cable with a socket wrench. Take out the rear seat cushion by pulling the seat stopper and lifting the lower cushion. Now, you can remove the access cover.

Unplug the fuel pump's electrical connection and disconnect the fuel send and return hose.

Now, you are ready to remove the retaining cap and the fuel pump. The retaining cap can be removed with tool MB991480. Once the retaining cap is off, you can then remove the fuel pump.

It is important to note that working with fuel can be dangerous, so ensure proper ventilation and take all necessary precautions to avoid starting a fire.

Install the new fuel pump and complete the installation by reversing the removal procedure

To install the new fuel pump, you will need to follow the steps outlined below:

Firstly, ensure that the packing material on the fuel tank is in good condition. If it is damaged or deformed, replace it with a new one. Then, install the new fuel pump, aligning the marks on the floor pan and the fuel pump.

Next, reconnect the electrical connections to the fuel pump cap and slide the fuel pump/fuel filter back into the cap, ensuring that the electrical connection to the top of the fuel pump is secure.

After that, reassemble the fuel pump assembly by inserting the fuel pump with the crown into the grommet and sliding the steel 'o-ring' back onto the fuel pickup sock. Reattach the fuel pickup sock to the bottom of the fuel pump and ensure that the "moon" shape is facing the correct direction. Seat the fuel filter/fuel pump assembly into the fuel reservoir, ensuring that all tabs are properly clasped.

Position the floating spring and the spring that surrounds the pickup line from the cap of the fuel pump assembly. Reconnect all electrical connections and the pickup line to the outside of the fuel reservoir.

Finally, reinstall the fuel pump assembly back into the car. Pull the black grommet off the top of the fuel assembly and place it on the gas tank first. Push down on the fuel pump assembly to keep it sealed in the gas tank while manoeuvring the black ring back into place and catching the threads. Screw the black ring back in, ensuring that the arrow triangle on the fuel pump assembly matches the mark on the black ring. Check that the ring is flush against the fuel pump assembly and that the assembly is secure and does not move up and down.

To complete the installation, reverse the removal procedure by reconnecting the fuel lines and electrical harnesses and screwing the lid plate back over the hole. Reinstall the rear seat cushion by threading the seat belt locks through the seat and locking it into the clips.

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