Vue 2006-2007

Removal & Installation

Print

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 sending units and float assemblies in the fuel tank-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 a hoist.

  1. Evacuating the fuel tank while vehicle is 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.

    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. Connecting SA9127E Fuel Pressure Gauge

    8.  
    9. Disconnect the fuel pressure gauge from the fuel pressure connection.
    10.  
    11. 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.
    12.  
    13. Connect a suitable drain hose to the other end of the adapter and connect the drain hose into a certified fuel handling cart.
    14.  
    15. Connect the scan tool to the vehicle and turn the ignition ON .
    16.  
    17. Energize the fuel pump using the scan tool.
    18.  
    19. Pump out the fuel until no more than 1 / 4  tank remains.
    20.  

  2.  
  3. Evacuating the fuel tank while vehicle is 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.
    8.  

  4.  
  5. Disconnect the fuel pressure gauge from the fuel pressure connection.
  6.  
  7. Disconnect the negative battery cable.
    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.

  8.  
  9. 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.
  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:
    1. Place the transaxle in neutral.
    2.  
    3. Index mark the relationship of the propeller shaft to the rear drive module flange.
    4.  
    5. Remove the bolts securing the underbody guard loop.
    6.  
    7. Remove the underbody guard loop

      Click image to see an enlarged view

      Fig. Remove underbody guard loop

    8.  
    9. Place a support under the propeller shaft at the rear drive module.
    10.  
    11. Remove the bolts securing the propeller shaft yoke flange to the rear drive module flange.
    12.  
    13. Index mark the relationship of the propeller shaft to the Power Take-off Unit (PTU) flange.
    14.  
    15. Place a support under the propeller shaft at the PTU.
    16.  
    17. Remove the bolts securing the propeller shaft to the PTU flange.
    18.  
    19. Place a support under the propeller shaft at the support bearing.
    20.  
    21. 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

    22.  
    23. While supporting the propeller shaft, move the propeller shaft rearward to disengage the constant velocity joint from the PTU flange.
    24.  
    25. Remove the propeller shaft from the vehicle.
    26.  

  14.  
  15. 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.  

  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 in. (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. 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.  

  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.
  30.  
  31. Remove the primary fuel pump module.
  32.  
  33. 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.

  34.  
  35. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.
  36.  
  37. 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°.

  38.  
  39. 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.

  40.  
  41. Discard the fuel pump module-to-tank seal.
  42.  
  43. Remove the fuel level sending unit.

    Click image to see an enlarged view

    Fig. Remove fuel level sensor

  44.  
  45. Release the retaining tabs (1, 2) and remove the level sensor by sliding up.
  46.  

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.  

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 sending units and float assemblies in the fuel tank-1 located on each fuel pump module. The fuel level sending 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 sending 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.  
  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°.



    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. Remove the fuel level sending unit.
  22.  

To install:

  1. Install the fuel level sending unit into the fuel pump.
  2.  
  3. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender cap snaps into place.
  4.  
  5. Connect the suction port.
  6.  
  7. Insert the new secondary fuel pump module with the level sender and new fuel pump-to-tank seal. Ensure the orientation tabs are aligned.
  8.  
  9. Use the SA9156E to install the fuel pump lock ring.
  10.  
  11. Connect the EVAP line quick connect.
  12.  
  13. Install the fuel tank.
  14.  

2.4L 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.

  1. Remove the fuel pump. Refer to Fuel Pump, removal & installation.
  2.  
  3. Remove the fuel level sensor wiring harness from the clip on the pump.
  4.  
  5. Disconnect the fuel level sensor electrical connector from the pump electrical connector.
  6.  
  7. Push the tab on the sensor in towards the sensor and remove the level sensor from the module alignment feature.

    Click image to see an enlarged view

    Fig. Push the tab (1) on the sensor in towards the sensor and remove the level sensor from the module alignment feature (3)

  8.  

To install:

  1. Installation is the reverse of removal.
  2.  

3.5L Engine




NOTE
There are 2 fuel level sending units and float assemblies in the fuel tank-1 located on each fuel pump module. The fuel level sending 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 use of a hammer or screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

  6.  
  7. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.
  8.  
  9. 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°.

  10.  
  11. 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.

  12.  
  13. Discard the fuel pump module-to-tank seal.
  14.  
  15. If the fuel level sending unit is being replaced, remove the fuel level sender.
  16.  
  17. Remove the secondary fuel pump module.
  18.  
  19. Disconnect the EVAP vent line quick connect.
  20.  
  21. Use the SA9156E Fuel Tank Lock Ring Remover or equivalent and remove the fuel pump module retaining ring.
  22.  
  23. Disconnect the secondary level sensor electrical connector.
  24.  
  25. 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°.

  26.  
  27. 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.

  28.  
  29. Discard the fuel pump module-to-tank seal.
  30.  
  31. If the fuel level sending unit is not being replaced as well, remove the fuel level sender.
    NOTE
    Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.


    NOTE
    Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.


    NOTE
    Check the lock ring for flatness.

  32.  
  33. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
    1. If warpage is less than 0.016 inches (0.41mm), the lock ring does not require replacement.
    2.  
    3. If warpage is greater than 0.016 inches (0.41mm), the lock ring must be replaced.
    4.  

  34.  

To install:

  1. Install the fuel level sending unit onto the fuel pump.
  2.  
  3. Insert the new primary fuel pump module assembly with the level sender and the new fuel pump-to-tank seal. Ensure the orientation tabs are aligned.
    NOTE
    Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.

  4.  
  5. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  6.  
  7. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
  8.  
  9. Connect the wiring harness to the primary fuel pump module and fuel tank pressure sensor.
  10.  
  11. Install the secondary fuel pump module.
  12.  
  13. Install the fuel tank.
  14.  

 
label.common.footer.alt.autozoneLogo