Vue 2002-2005

Removal & Installation

Imprimir

2.2L Engine



Primary

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.


NOTE
There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1 located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of the fuel pump modules.


CAUTION
Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

  1. Ensure that the fuel level in the tank is less than 1 / 4 full. If necessary, drain the fuel tank.
    CAUTION
    Never drain or store fuel in an open container due to the possibility of fire or explosion.

  2.  

Using the fuel pump to drain the tank is the easiest procedure if the pump is operable. The fuel can be pumped out with the vehicle on the ground or on the hoist.

On a Hoist

CAUTION
Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

  1. Connect the scan tool to the vehicle diagnostic connector and turn the ignition ON .
  2.  
  3. Relieve the fuel system pressure.
    CAUTION
    Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

  4.  
  5. Connect the SA9127E or equivalent to the fuel pressure connection.
  6.  
  7. Install the bleed hose (3) into an approved container and open the valve (5) to bleed the system pressure. The fuel connections are now safe for servicing.

    Click image to see an enlarged view

    Fig. Connect SA9127E Fuel Pressure Gauge

  8.  
  9. Disconnect the fuel pressure gauge from the fuel pressure connection.
    CAUTION
    Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  10.  
  11. Raise the vehicle on a hoist to a comfortable working height, keeping the scan tool outside of the vehicle and accessible from under the car.
  12.  
  13. Disconnect the negative battery cable.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Remove the rubber exhaust hangers on order to allow the exhaust system to drop slightly.
  18.  
  19. Remove the propeller shaft, if equipped.
    1. Place the transmission in neutral.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Index mark the relationship of the propeller shaft to the rear drive module flange.
    6.  
    7. Remove the bolts securing the underbody guard loop.
    8.  
    9. Remove the underbody guard loop

      Click image to see an enlarged view

      Fig. Remove underbody guard loop

    10.  
    11. Place a support under the propeller shaft at the rear drive module.
    12.  
    13. Remove the bolts securing the propeller shaft yoke flange to the rear drive module flange.
    14.  
    15. Index mark the relationship of the propeller shaft to the Power Take-off Unit (PTU) flange.
    16.  
    17. Place a support under the propeller shaft at the PTU.
    18.  
    19. Remove the bolts securing the propeller shaft to the PTU flange.
    20.  
    21. Place a support under the propeller shaft at the support bearing.
    22.  
    23. Remove the bolts securing the propeller shaft support bearing to the vehicle underbody.

      Click image to see an enlarged view

      Fig. Remove bolts securing the propeller shaft support bearing to the vehicle underbody

    24.  
    25. While supporting the propeller shaft, move the propeller shaft rearward to disengage the constant velocity joint from the PTU flange.
    26.  
    27. Remove the propeller shaft from the vehicle.
    28.  

  20.  
  21. Disconnect the EVAP canister vent and fresh air hoses:
    1. Grasping both sides of the quick-connect fitting, twist the female connector 1/4 turn in each direction in order to loosen dirt within the quick-connect fitting.
    2.  
    3. Blow any dirt out of the quick-connect fitting using compressed air.
    4.  
    5. Squeeze the plastic retainer release tabs.
    6.  
    7. Pull the connection apart.
    8.  
    9. Inspect both ends of the quick-connect fitting for dirt and burrs.
    10.  

  22.  
  23. Remove the fuel filler pipe, EVAP vent hose, and fresh air hose from the fuel tank.
    CAUTION
    Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 12 in. (300mm) diameter to adequately catch the fluid.

  24.  
  25. Disconnect the chassis fuel supply line from the tank.
  26.  
  27. Disconnect the electrical connectors:
    1. Fuel tank electrical connectors
    2.  
    3. EVAP solenoid electrical connector
      NOTE
      Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.


      NOTE
      Do not disassemble the RDM. It is not necessary to touch the RDM for fuel tank removal.

    4.  

  28.  
  29. Support the fuel tank.
  30.  
  31. Remove the fuel tank strap bolts and fuel tank straps.
  32.  
  33. Lower the fuel tank from the underbody of the vehicle.
  34.  
  35. Remove the fuel tank.
  36.  
  37. Remove the primary fuel pump module.
  38.  
  39. Disconnect the electrical connectors from the primary fuel pump module and fuel tank pressure sensor.
    NOTE
    Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.


    NOTE
    Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.


    WARNING
    Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer or screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

  40.  
  41. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.
  42.  
  43. Disconnect the fuel feed and vent lines from the fuel tank.
    NOTE
    To prevent bending of the sending unit float arm during removal, lift the pump module up slightly to disengage the orientation tabs in the tank and rotate the module 45 degrees.

  44.  
  45. Remove the primary fuel pump module assembly.
    NOTE
    Always replace the fuel pump module-to-tank seal, O-ring, when the fuel pump module is removed.

  46.  
  47. Discard the fuel pump module-to-tank seal.
  48.  
  49. If the fuel level sending unit is being replaced, remove the fuel level sender.

    Click image to see an enlarged view

    Fig. Remove level sensor

  50.  
  51. Release the retaining tabs (1, 2) and remove the level sensor by sliding up.
  52.  

To install:

  1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender cap snaps into place (1, 2).
  2.  
  3. Connect the fuel level sender unit and float electrical connector.
  4.  
  5. Install the fuel pump module into the fuel tank.
  6.  
  7. Install the fuel tank..
  8.  

On The Ground

CAUTION
Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

  1. Remove the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
    CAUTION
    Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

    1. Connect the SA9127E or equivalent to the fuel pressure connection.
    2.  
    3. Install the bleed hose (3) into an approved container and open the valve (5) to bleed the system pressure. The fuel connections are now safe for servicing.

      Click image to see an enlarged view

      Fig. Connect SA9127E Fuel Pressure Gauge

    4.  
    5. Disconnect the fuel pressure gauge from the fuel pressure connection.
    6.  

  4.  
  5. Disconnect the fuel feed line at the fuel rail and install the 3 / 8 inch x  1 / 4 inch quick connect from the SA9127E into the fuel feed line.
  6.  
  7. Connect a suitable drain hose to the other end of the adapter and connect the drain hose into a certified fuel handling cart.
  8.  
  9. Connect the scan tool to the vehicle and turn the ignition ON .
  10.  
  11. Energize the fuel pump using the scan tool.
  12.  
  13. Pump out the fuel until no more than 1/4 tank remains.
  14.  

Secondary

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.


NOTE
There are 2 fuel level sender units and float assemblies in the fuel tank. There is 1 located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of the fuel pump modules.

  1. Remove the fuel tank
  2.  
  3. Remove the fuel pump module.
  4.  
  5. Disconnect the fuel level sender unit and the float electrical connector.
  6.  
  7. Release the retaining tabs and remove the level sensor by sliding up.
    CAUTION
    Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.


    WARNING
    Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.

  8.  
  9. Disconnect the EVAP vent line quick connect.  
    WARNING
    To prevent retainer damage, do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar.

  10.  
  11. Use the SA9156E Fuel Tan Lock Ring Remover or equivalent and remove the fuel pump module retaining ring.
  12.  
  13. Disconnect the secondary level sensor electrical connector.
  14.  
  15. Disconnect the suction port attaching tube by pressing down on the tab (1).
    NOTE
    To prevent bending of the sending unit float arm during removal, lift the pump module up slightly to disengage the orientation tabs in the tank and rotate the module 45 degrees.



    Click image to see an enlarged view

    Fig. Disconnect suction port attaching tube

  16.  
  17. Remove the secondary fuel pump module.
    NOTE
    Always replace the fuel pump module-to-tank seal, O-ring, when the fuel pump module is removed.

  18.  
  19. Discard the fuel pump module-to-tank seal.
  20.  
  21. If the fuel level sending unit is not being replaced as well, remove the fuel level sender.
  22.  

To install:

  1. If the fuel level sending unit is being replaced, install the fuel level sending unit into the new fuel pump.
    1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender cap snaps into place.
    2.  

  2.  
  3. Connect the suction port.
  4.  
  5. Insert the new secondary fuel pump module with the level sender and new fuel pump-to-tank seal. Ensure the orientation tabs are aligned.
  6.  
  7. Use the SA9156E to install the fuel pump lock ring.
  8.  
  9. Connect the EVAP line quick connect.
  10.  
  11. Install the fuel tank.
  12.  

3.0L Engine



Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.


NOTE
There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1 located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of the fuel pump modules.

  1. Remove the fuel tank.
    CAUTION
    Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

  2.  
  3. Ensure that the fuel level in the tank is less than 1 / 4  full. If necessary, drain the fuel tank to at least this level.
    CAUTION
    Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.


    CAUTION
    Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

  4.  
  5. Relieve the fuel system pressure, as follows:
    1. Disconnect the negative battery cable.
    2.  
    3. Connect the J 34730-1A or equivalent to the fuel pressure connection.
    4.  
    5. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing.
    6.  
    7. Disconnect the fuel pressure gauge from the fuel pressure connection.
    8.  

  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the rubber exhaust hangers on order to allow the exhaust system to drop slightly.
  10.  
  11. Remove the propeller shaft guard, if equipped.
  12.  
  13. Remove the propeller shaft, if equipped.
    NOTE
    Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

  14.  
  15. Disconnect the EVAP canister vent and fresh air hoses, as follows:
    1. Grasping both sides of the quick-connect fitting, twist the female connector 1/4 turn in each direction in order to loosen dirt within the quick-connect fitting.
    2.  
    3. Blow any dirt out of the quick-connect fitting using compressed air.
    4.  
    5. Squeeze the plastic retainer release tabs.
    6.  
    7. Pull the connection apart.
    8.  
    9. Inspect both ends of the quick-connect fitting for dirt and burrs.
    10.  

  16.  
  17. Remove the fuel filler pipe, EVAP vent hose, and fresh air hose from the fuel tank.
    CAUTION
    Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 12 inches (300mm) diameter to adequately catch the fluid.

  18.  
  19. Disconnect the chassis fuel supply line from the fuel filter outlet.
  20.  
  21. Disconnect the fuel tank ground strap fastener.
  22.  
  23. Disconnect the fuel tank electrical connector.
    WARNING
    Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.


    NOTE
    Do not disassemble the RDM. It is not necessary to touch the RDM for fuel tank removal.



    Click image to see an enlarged view

    Fig. Remove the fuel filler pipe, EVAP vent hose, and fresh air hose from the fuel tank.

  24.  
  25. Support the fuel tank.
  26.  
  27. Remove the fuel tank strap bolts and fuel tank straps.
  28.  
  29. Lower the fuel tank from the underbody of the vehicle.
  30.  

Primary
  1. Place the fuel tank in a suitable work area.
  2.  
  3. Remove the primary fuel pump module from the fuel tank, as follows:
  4.  
  5. Disconnect the fuel lines from the fuel pump module.
  6.  
  7. Disconnect the EVAP vent line from the primary fuel pump module.

    Click image to see an enlarged view

    Fig. Disconnect the fuel lines from the fuel pump module.

  8.  
  9. Disconnect the electrical connector from the primary fuel pump module.
    WARNING
    To prevent retainer damage, do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar.



    Click image to see an enlarged view

    Fig. Disconnect the electrical connector from the primary fuel pump module.

  10.  
  11. Use the SA9156E or equivalent and remove the fuel pump module retaining ring. A 1 / 2  in. breaker bar, approximately 18 inches (45.7 cm) long, will easily loosen and remove the lock ring.
    NOTE
    To prevent bending of the sending unit float arm during removal, lift the pump module up slightly to disengage the orientation tabs in the tank and rotate the module 45 degrees.



    Click image to see an enlarged view

    Fig. Remove the lock ring

  12.  
  13. Remove the primary fuel pump module.
    NOTE
    Always replace the fuel pump module-to-tank seal, H-ring, when the fuel pump module is removed.

  14.  
  15. Discard the fuel pump module-to-tank seal.
  16.  
  17. If the fuel level sending unit is not being replaced, remove the fuel level sender, as follows:
    1. Disconnect the fuel level sender unit and float electrical connector.
    2.  
    3. Use a small screwdriver to release the double-sided snap lock feature.
    4.  
    5. Remove the fuel level sender card by sliding the card down.
    6.  

  18.  

To install:

  1. Install the fuel level sending unit onto the new fuel pump as follows:
    1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender cap snaps into place.
    2.  
    3. Connect the fuel level sender unit and float electrical connector.
    4.  

  2.  
  3. Insert the new primary fuel pump module with the level sender and the new fuel pump-to-tank seal. Ensure the orientation tabs are aligned.
  4.  
  5. Use the SA9156E to install the fuel pump lock ring.
    NOTE
    New fuel line quick connect retainers must be used.

  6.  
  7. Connect the fuel lines, EVAP line, and wiring harness to the primary fuel pump module.
  8.  
  9. Install the fuel tank.
  10.  

Secondary
  1. Disconnect the fuel line from the secondary fuel pump module.
  2.  
  3. Disconnect the EVAP vent line from the secondary fuel pump module.
  4.  
  5. Disconnect the fuel level sender and fuel tank pressure sensor electrical connectors.
    WARNING
    To prevent retainer damage, do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar.



    Click image to see an enlarged view

    Fig. Disconnect the fuel level sender and fuel tank pressure sensor electrical connectors.

  6.  
  7. Use the SA9156E or equivalent and remove the fuel pump module retaining ring. A 1 / 2  in. breaker bar, approximately 18 inches (45.7 cm) long, will easily loosen and remove the lock ring.
  8.  
  9. Remove the secondary fuel pump module.
    NOTE
    Always replace the fuel pump module-to-tank seal, H-ring, when the fuel pump module is removed.



    Click image to see an enlarged view

    Fig. Remove the secondary fuel pump module.

  10.  
  11. If the fuel level sending unit is not being replaced as well, remove the fuel level sender as follows:
  12.  
  13. Disconnect the fuel level sender unit and float electrical connector.
  14.  
  15. On the secondary module assembly, use a pick to press down on the silver connector and disconnect the ground wire from the fuel pressure regulator.
  16.  
  17. Use a small screwdriver to release the double-sided snap lock feature shown in the exploded view.

    Click image to see an enlarged view

    Fig. Use a small screwdriver to release the double-sided snap lock feature.

  18.  
  19. Remove the fuel level sender card by sliding the card down.
  20.  

To install:

  1. Install the fuel level sending unit into the new fuel pump, as follows:
    1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender cap snaps into place.
    2.  
    3. Connect the fuel level sender unit and float electrical connector.
    4.  
    5. Connect the ground wire to the fuel pressure regulator.
    6.  

  2.  
  3. Insert the new secondary fuel pump module with the level sender and new fuel pump-to-tank seal. Ensure the orientation tabs are aligned.
  4.  
  5. Use the SA9156E to install the fuel pump lock ring.
    NOTE
    New fuel line quick connect retainers must be used.

  6.  
  7. Connect the fuel lines and wiring harness to the secondary fuel pump module.
  8.  
  9. Install the fuel tank.
  10.  

3.5L Engine




NOTE
There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1 located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of the fuel pump modules.

  1. Remove the fuel tank.
  2.  
  3. Remove the fuel pump module.
    CAUTION
    Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.


    CAUTION
    Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.

  4.  
  5. Disconnect the electrical connectors from the primary fuel pump module and fuel tank pressure sensor.  
    WARNING
    Avoid damaging the lock ring. Use only J-45722 Fuel Tank Lock Ring Remover to prevent damage to the lock ring.


    WARNING
    Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.


    WARNING
    Do NOT use impact tools. Significant force will be required to release the lock ring. The u