LEMON Manuals: Even more car manuals for everyone
Home >> Mitsubishi >> 2003 >> Outlander XLS, FWD >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Combination Meters Assembly & Vehicle Speed >> Symptom Procedures >> INSPECTION PROCEDURE 3: Fuel Gauge does not Work >> Diagnosis

INSPECTION PROCEDURE 3: Fuel Gauge does not Work: Diagnosis

Required Special Tool: 

  1. MB991223: Harness Set
  1. STEP 1. Check with other meter. 

    Check to see that the speedometer, fuel gauge and water thermometer operate normally.

    Q: Do all other meters operate? 

    1. YES < other meters all operate. > :  Go to Step 2.
    2. NO < one of the meters do not operate. > :  Refer to INSPECTION PROCEDURE 5  .
  2. STEP 2. Check the malfunctioning vehicle. 

    Q: Is the malfunctioning vehicle a FWD? 

    1. YES < FWD > :  Go to Step 3.
    2. NO < AWD > :  Go to Step  9) .
  3. STEP 3. Check the fuel gauge unit. 

    Check to see if the fuel gauge is normal. Refer to TACHOMETER CHECK  .

    Q: Is the fuel gauge unit normal? 

    1. YES:  Go to Step 4.
    2. NO:  Replace the fuel gauge unit. The fuel gauge should work normally.
  4. STEP 4. Measure at fuel gauge unit connector D-14 in order to the ground circuit to the fuel gauge unit. 
    1. Disconnect fuel gauge unit connector D-14, and measure at the wiring harness side.
      Fig 1: Locating Fuel Gauge Unit Connector D-14
      G01861040Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Measure the resistance value between terminal 2 and ground.
      • The measured value should be 2 ohm or less.

    Q: Does the measured resistance value correspond with this range? 

    1. YES:  Go to Step  7) .
    2. NO:  Go to Step 5.
    Fig 2: Measuring Resistance Between Terminal 2 & Ground
    G01861041Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  5. STEP 5. Check fuel gauge unit connector D-14 for damage. 

    Q: Is fuel gauge unit connector D-14 in good condition? 

    1. YES:  Go to Step 6.
    2. NO:  Repair or replace the connector. The fuel gauge should work normally.
    Fig 3: Locating Fuel Gauge Unit Connector D-14
    G01861042Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  6. STEP 6. Check the wiring harness between fuel gauge unit connector D-14 (terminal 2) and ground. 
    NOTE: Also check intermediate connector D-22. If intermediate connector D-22 is damaged, repair or replace the connector.

    Q: Is the wiring harness between fuel gauge unit connector D-14 (terminal 2) and ground in good condition? 

    1. YES:  There is no action to be taken.
    2. NO:  Repair the wiring harness. The fuel gauge should work normally.
    Fig 4: Locating Fuel Gauge Unit Connector D-14 & Intermediate Connector D-22
    G01861043Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  7. STEP 7. Check fuel gauge unit connector D-14 and combination meter connector C-04 for damage. 

    Q: Are fuel gauge unit connector D-14 and combination meter connector C-04 in good condition? 

    1. YES:  Go to Step 8.
    2. NO:  Repair or replace the connector. The fuel gauge should work normally.
    Fig 5: Locating Combination Meter Connector C-04
    G01861044Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 6: Locating Fuel Gauge Unit Connector D-14
    G01861045Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  8. STEP 8. Check the wiring harness between fuel gauge unit connector D-14 (terminal 1) and combination meter connector C-04 (terminal 43). 
    NOTE: Also check intermediate connectors C-117 and D-22. If intermediate connector C-117 or D-22 are damaged, repair or replace the connector.

    Q: Are the wiring harness between fuel gauge unit connector D-14 (terminal 1) and combination meter connector C-04 (terminal 43) in good condition? 

    1. YES:  Repair or replace the combination meter. The fuel gauge should work normally.
    2. NO:  Repair the wiring harness. The fuel gauge should work normally.
    Fig 7: Locating Combination Meter Connector C-04 & Intermediate Connector C-117
    G01861046Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 8: Locating Fuel Gauge Unit Connector D-14 & Intermediate Connector D-22
    G01861047Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  9. STEP 9. Check the fuel gauge unit (sub) and fuel gauge unit (main). 

    Check to see that the fuel gauge unit (sub) and fuel gauge unit (main) are normal. Refer to FUEL GAUGE UNIT FLOAT HEIGHT  .

    Q: Are fuel gauge unit (sub) and fuel gauge unit (main) normal? 

    1. YES:  Go to Step 10.
    2. NO:  Replace fuel gauge unit (sub) and fuel gauge unit (main). The fuel gauge should work normally.
  10. STEP 10. Measure at fuel pump and gauge unit connector D-15 in order to the ground circuit to the fuel pump and gauge unit. 
    1. Disconnect fuel gauge unit connector D-15, and measure at the wiring harness side.
      Fig 9: Locating Fuel Pump & Gauge Unit Connector D-15
      G01861048Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Measure the resistance value between terminal 1 and ground.
      • The measured value should be 2 ohms or less.

    Q: Does the measured resistance value correspond with this range? 

    1. YES:  Go to Step  13) .
    2. NO:  Go to Step 11.
    Fig 10: Measuring Resistance Value Between Terminal 1 & Ground
    G01861049Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  11. STEP 11. Check fuel pump and gauge unit connector D-15 for damage. 

    Q: Is fuel pump and gauge unit connector D-15 in good condition? 

    1. YES:  Go to Step 12.
    2. NO:  Repair or replace the connector. The fuel gauge should work normally.
    Fig 11: Locating Fuel Pump & Gauge Unit Connector D-15
    G01861050Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  12. STEP 12. Check the wiring harness between fuel pump and gauge unit connector D-15 (terminal 1) and ground. 
    NOTE: Also check intermediate connector D-22. If intermediate connector D-22 is damaged, repair or replace the connector.

    Q: Is the wiring harness between fuel pump and gauge unit connector D-15 (terminal 1) and ground in good condition? 

    1. YES:  There is no action to be taken.
    2. NO:  Repair the wiring harness. The fuel gauge should work normally.
    Fig 12: Locating Fuel Pump & Gauge Unit Connector D-15 & Intermediate Connector D-22
    G01861051Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  13. STEP 13. Check fuel gauge unit connector D-11 and combination meter connector C-04 for damage. 

    Q: Are fuel gauge unit connector D-11 and combination meter connector C-04 in good condition? 

    1. YES:  Go to Step 14.
    2. NO:  Repair or replace the connector. The fuel gauge should work normally.
    Fig 13: Locating Combination Meter Connector C-04
    G01861052Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 14: Locating Fuel Gauge Unit Connector D-11
    G01861053Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  14. STEP 14. Check the wiring harness between fuel gauge unit connector D-11 (terminal 1) and combination meter connector C-04 (terminal 43). 
    NOTE: Also check intermediate connectors C-117 and D-22. If intermediate connector C-117 or D-22 are damaged, repair or replace the connector.

    Q: Are the wiring harness between fuel gauge unit connector D-11 (terminal 1) and combination meter connector C-04 (terminal 43) in good condition? 

    1. YES:  Go to Step 15.
    2. NO:  Repair the wiring harness. The fuel gauge should work normally.
    Fig 15: Locating Combination Meter Connector C-04 & Intermediate Connector C-117
    G01861054Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    Fig 16: Locating Fuel Gauge Unit Connector D-11 & Intermediate Connector D-22
    G01861055Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  15. STEP 15. Check fuel gauge unit connector D-11 and fuel pump and gauge unit connector D-15 for damage. 

    Q: Are fuel gauge unit connector D-11 and fuel pump and gauge unit connector D-15 in good condition? 

    1. YES:  Go to Step 16.
    2. NO:  Repair or replace the connector. The fuel gauge should work normally.
    Fig 17: Locating Fuel Gauge Unit Connector D-11 & Fuel Pump & Gauge Unit Connector D-15
    G01861056Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
  16. STEP 16. Check the wiring harness between fuel gauge unit connector D-11 (terminal 2) and fuel pump and gauge unit connector D-15 (terminal 2). 

    Q: Are the wiring harness between fuel gauge unit connector D-11 (terminal 2) and fuel pump and gauge unit connector D-15 (terminal 2) in good condition? 

    1. YES:  Repair or replace the combination meter. The fuel gauge should work normally.
    2. NO:  Repair the wiring harness. The fuel gauge should work normally.
    Fig 18: Locating Fuel Gauge Unit Connector D-11 & Fuel Pump & Gauge Unit Connector D-15
    G01861057Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
scientia non olet · About LEMON Manuals