2004 Chrysler Intrepid SXTFACTORY OEM SERVICE PROCEDURE

Fuel Pump Module: Removal

  1. Release fuel pressure. Refer to STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
  2. Remove Fuel Tank refer to the FUEL TANK .
    WARNING: THE FUEL RESERVOIR OF THE FUEL PUMP MODULE DOES NOT EMPTY OUT WHEN THE TANK IS DRAINED. THE FUEL IN THE RESERVOIR WILL SPILL OUT WHEN THE MODULE IS REMOVED.
  3. Disconnect fuel line from fuel pump module by depressing quick connect retainers with thumb and fore finger.
  4. Slide fuel pump module electrical connector lock to unlock.
  5. Disconnect the electrical connection from the fuel pump module, by pushing down on connector retainer and pulling connector off of module.
  6. Use Special Tool #6856 to remove fuel pump module locknut (Fig 1).
    Fig 1: Fuel Tank Locknut
    G03498657Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove fuel pump and O-ring seal from tank. Discard old seal.
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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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