1. Preparation:
* Safety First: Work in a well-ventilated area. Fuel vapors are highly flammable. Wear safety glasses and gloves. Have a fire extinguisher nearby.
* Gather Tools: You'll need a variety of tools, including:
* Socket wrench set (metric)
* Ratchet and extensions
* Torque wrench
* Screw drivers (Phillips and flathead)
* Pliers
* Fuel line disconnect tool (essential to avoid damage)
* Jack and jack stands (crucial for safety)
* Drain pan
* Shop rags
* New fuel pump (ensure you get the correct one for your model and engine)
* Possibly a fuel pressure gauge (helps confirm the old pump's issue)
2. Accessing the Fuel Pump:
* Lower the Fuel Tank: This is usually the most challenging part. You'll need to access the fuel pump through the access panel typically located under the rear seat (some models may require access from underneath the car). You may need to remove the spare tire and other items to get enough space to work. Consult your repair manual for the exact location. Once located, you'll need to lower the fuel tank. This often involves disconnecting the fuel filler neck, fuel lines, and the electrical connector.
* Support the tank carefully! It's heavy and contains fuel. Use jack stands to securely support it once lowered.
* Disconnect Fuel Lines: This is critical. Use the fuel line disconnect tool to carefully separate the fuel lines from the fuel pump module. Have rags ready to absorb any spilled fuel. Never work near an ignition source.
3. Replacing the Fuel Pump:
* Remove the Fuel Pump Assembly: Once the fuel lines and electrical connector are disconnected, you can remove the fuel pump assembly from the tank. This usually involves removing bolts or clamps. Refer to your repair manual for precise instructions.
* Install the New Fuel Pump: Install the new fuel pump into the assembly, ensuring a proper seal. Double-check the orientation of the pump to match the old one.
* Reassemble: Carefully reassemble the fuel pump assembly, paying attention to the gasket or O-ring to ensure a leak-free seal.
4. Reinstallation:
* Reconnect Fuel Lines and Electrical Connector: Carefully reconnect the fuel lines and the electrical connector to the fuel pump assembly. Ensure secure connections.
* Raise the Fuel Tank: Carefully raise the fuel tank back to its original position. Securely bolt it back in place.
* Reconnect Fuel Filler Neck: Reconnect the fuel filler neck.
* Reconnect Battery: Reconnect the battery's negative terminal.
5. Testing:
* Check for Leaks: After everything is reconnected, carefully inspect all connections for any leaks.
* Start the Engine: Start the engine and let it run for a few minutes to ensure the new fuel pump is working correctly. Listen for unusual noises. Check for any fuel leaks.
* Check Fuel Pressure (Optional): If you have a fuel pressure gauge, you can check the fuel pressure to confirm the new pump is delivering the correct pressure.
Important Considerations:
* Repair Manual: A repair manual specific to your year and model of Dodge Intrepid is highly recommended. This will provide detailed, step-by-step instructions and diagrams, making the process much safer and easier.
* Fuel System Pressure: The fuel system might be pressurized. Take precautions to relieve pressure before disconnecting any fuel lines.
* Professional Help: If you're not comfortable working on your car, it's best to take it to a qualified mechanic. Improperly installing a fuel pump can lead to serious problems.
This is a general overview. Always consult a repair manual specific to your vehicle's year and model for detailed instructions. Improperly performing this repair could lead to damage to your vehicle or personal injury. If you are unsure about any step, seek professional help.
