Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2000 Chrysler Intrepid (CANADA) V6-3.2LFACTORY OEM SERVICE PROCEDURE
Fuel Level Sensor: Service and Repair
REMOVAL
Remove fuel pump module.
1. Depress the retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector.
2. Remove wire terminal retaining clip from connector. Note the location of terminals for the level sensor wires.
3. Using special tool 7812 or an equivalent, push sensor signal and ground terminals out of the connector.
4. Insert a screwdriver between the fuel pump module and the top of the level sensor housing Push level sensor down slightly.
5. Slide level sensor wires through stand pipe inside fuel pump module.
6. Slide level sensor out of installation channel.
INSTALLATION
1. Insert level sensor wires in bottom of stand pipe.
2. Wrap wires into groove in back of level sensor.
3. while feeding wires into stand pipe, slide level sensor up into installation channel until it snaps into place. Ensure tab at bottom of sensor locks in place.
4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position.
5. Install retaining clip on connector.
6. Push fuel pump/level sensor connector up into bottom of fuel pump module electrical connector.
7. Install fuel pump module.
Remove fuel pump module.
Fuel Pump/Level Sensor Connector:
1. Depress the retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector.
Wire Terminal Retaining Clip:
Wire Terminal Identification:
2. Remove wire terminal retaining clip from connector. Note the location of terminals for the level sensor wires.
Level Sensor Signal And Ground Wires:
3. Using special tool 7812 or an equivalent, push sensor signal and ground terminals out of the connector.
Fuel Level Sensor Removal:
4. Insert a screwdriver between the fuel pump module and the top of the level sensor housing Push level sensor down slightly.
Standpipe Inside Module:
5. Slide level sensor wires through stand pipe inside fuel pump module.
6. Slide level sensor out of installation channel.
INSTALLATION
1. Insert level sensor wires in bottom of stand pipe.
Level Sensor Installation:
2. Wrap wires into groove in back of level sensor.
3. while feeding wires into stand pipe, slide level sensor up into installation channel until it snaps into place. Ensure tab at bottom of sensor locks in place.
4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position.
5. Install retaining clip on connector.
6. Push fuel pump/level sensor connector up into bottom of fuel pump module electrical connector.
7. Install fuel pump module.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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