2004 Chrysler Intrepid SXTFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Installation

  1. Raise the fuel tank on the transmission stand (Figure).
  2. Install fuel pump electrical connector into hole in the body.
  3. Connect wiring harness to fuel tank pin, if removed (Figure).
  4. Connect wiring harness to heat shield, if removed (Figure).
  5. Connect the purge and vent lines (Figure).
  6. Raise tank into position and install tank straps.
  7. Install the fuel filler tube and tighten the clamp (Figure).
  8. Reposition the stabilizer bar and install bolts.
  9. Lower vehicle.
  10. Connect the fuel pump electrical connector that is under the rear seat (Figure).
  11. Install the rear seat, refer to SEATS for more information.
  12. Connect the battery cable (Figure).
  13. Fill fuel tank. Use the DRB scan tool to pressurize the fuel system. Check for leaks.
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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