Vue 2002-2005

Removal & Installation

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2.2L & 3.5L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
    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
    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.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Raise and support the vehicle .
  10.  
  11. Remove the rubber exhaust hangers on order to allow the exhaust system to drop slightly.
  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 Evaporative Emission (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.  

  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 tank.
  20.  
  21. Disconnect the electrical connectors:
    1. The fuel tank electrical connectors.
    2.  
    3. The EVAP solenoid 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 Rear Drive Module (RDM). It is not necessary to touch the RDM for fuel tank removal.

    4.  

  22.  
  23. Support the fuel tank.
  24.  
  25. Remove the fuel tank strap bolts and fuel tank straps.
  26.  
  27. Lower the fuel tank from the underbody of the vehicle.
  28.  
  29. Remove the fuel tank module assemblies.
  30.  

To install:

  1. Install the fuel tank module assemblies.
  2.  
  3. Install the fuel tank heat shield and fuel tank assembly into the vehicle.
  4.  
  5. Install the fuel tank straps and tighten the bolts. Tighten the fuel tank strap-to-body bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the fuel filler pipe, EVAP vent, and fresh air hoses to the fuel tank.
  8.  
  9. Connect the electrical connectors:
    1. The fuel tank electrical connector.
    2.  
    3. The EVAP solenoid electrical connectors.
    4.  

  10.  
  11. Tighten the hose clamp on the filler pipe-to-fuel tank connecting hose. Tighten the fuel fill neck-to-fuel tank clamp to 44 inch lbs. (5 Nm).
  12.  
  13. Connect the EVAP canister vent and fresh air hoses to the fuel tank hoses.
  14.  
  15. If equipped, install the propeller shaft.
  16.  
  17. Install the rubber exhaust hangers.
  18.  
  19. Lower the vehicle .
  20.  
  21. Fill the fuel tank with gasoline.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Prime the fuel system:
    1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
    2.  
    3. Repeat the previous step twice.
    4.  
    5. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    6.  
    7. If the engine does not start, repeat steps A-C.
    8.  

  26.  

2.4L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
    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
    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.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Raise and support the vehicle .
  10.  
  11. Remove the muffler.
  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 evaporative emission (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.  

  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 tank.
  20.  
  21. Disconnect the electrical connectors:
    1. The fuel tank electrical connectors.
    2.  
    3. The EVAP solenoid electrical connector.
    4.  

  22.  
  23. Remove the 36-volt battery positive cable, if equipped.
    WARNING
    Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.


    NOTE
    Do not disassemble the Rear Drive Module (RDM). It is not necessary to touch the RDM for fuel tank removal.

  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.  
  31. Remove the fuel tank module assemblies.
  32.  

To install:

  1. Install the fuel tank module assemblies.
  2.  
  3. Install the fuel tank heat shield and fuel tank assembly into the vehicle.
  4.  
  5. Install the fuel tank straps and tighten the bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the 36-volt battery positive cable, if equipped.
  8.  
  9. Install the fuel filler pipe, EVAP vent, and fresh air hoses to the fuel tank.
  10.  
  11. Connect the electrical connectors:
    1. The fuel tank electrical connector.
    2.  
    3. The EVAP solenoid electrical connectors.
    4.  

  12.  
  13. Tighten the hose clamp on the filler pipe-to-fuel tank connecting hose. Tighten the clamp to 44 inch lbs. (5 Nm).
  14.  
  15. Connect the EVAP canister vent and fresh air hoses to the fuel tank hoses.
  16.  
  17. Install the muffler.
  18.  
  19. If equipped, install the propeller shaft.
  20.  
  21. Lower the vehicle .
  22.  
  23. Fill the fuel tank with gasoline.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Prime the fuel system:
    1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
    2.  
    3. Repeat the previous step twice.
    4.  
    5. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    6.  
    7. If the engine does not start, repeat steps A-C.
    8.  

  28.  

 
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