Replacing Fuel Lines: 2000 Dodge Intrepid Guide

If you're looking to replace the fuel line on your 2000 Dodge Intrepid, you've come to the right place. This is a relatively simple procedure that can be done at home, but it's important to take the necessary precautions and follow the correct steps to ensure a safe and effective repair.

First, make sure you have the right parts and tools for the job. You can find fuel lines, hoses, gaskets, and seals from various manufacturers, such as Dorman, Mopar, and Spectra Premium, which offer direct-fit replacement parts for your Intrepid. It's also important to have the necessary tools, such as a fuel line disconnect tool, wrenches, and channel lock pliers.

Next, you'll need to relieve the fuel system pressure and disconnect the fuel pump relay. This is an important safety step to prevent any accidental fuel spray or leaks. You'll then need to remove the fuel tank and detach the fuel lines and electrical connectors from the fuel pump module. Be careful when handling these components, as they are crucial to your vehicle's performance and fuel efficiency.

Once the old fuel line is removed, you can install the new one. Make sure to line up the tabs and notches correctly and tighten any connections securely. Reattach the electrical connectors and fuel lines, and reinstall the fuel tank. Finally, reconnect the negative battery cable and start your vehicle to check for any leaks.

By carefully following these steps and paying attention to the specific parts and tools required for your 2000 Dodge Intrepid, you can successfully replace the fuel line and get your vehicle back on the road.

Removing the fuel tank

To remove the fuel tank from a 2000 Dodge Intrepid, you must first relieve the fuel system pressure. Take out the fuel filler cap and disconnect the fuel pump relay from the power distribution center in the engine compartment. Then, start your engine and leave it running until it dies. Crank the engine several times and remove the key from the ignition. Reattach the fuel pump relay, and remove the negative battery cable from the remote ground terminal on the right fender in the engine compartment.

Next, you will need to place the vehicle on a ramp or jack stands to access the underside of the vehicle. Remove the rear tires and pull the exhaust pipe hangers off the mounting studs on the frame rail at the rear of the vehicle and in front of the fuel tank. Mark the fuel filler hose, filler tube, vent hose, and vent tube with a grease pencil, and remove the splash shield from the passenger side rear wheel well. Remove the clamps from the fuel filler and vent hose, and disconnect the hoses from their respective tubes. Disconnect the fuel supply tube from the inlet side of the fuel filter, and disconnect the fuel return tube and vent tube near the fuel filter.

Now, you will need to access the crossmember. Disconnect both ends of the sway bar from the stabilizer links and mark the position of the crossmember ends on the frame rail. Remove the crossmember mounting bolts and pull the crossmember down. Place a transmission jack under the fuel tank and remove the sway bar mounting brackets, heat shield, and fuel tank strap. Lower the jack enough to access the fuel line and electrical connections on the fuel pump module at the top of the tank. Disconnect the electrical connector from the fuel pump module.

Finally, you can remove the fuel tank. Slightly lower the front of the tank and slide it away from the crossmember, pushing the filler vent and fill tube over the crossmember. Carefully lower the fuel tank and place it in a safe location.

Disconnecting the fuel lines

Before beginning, it is important to relieve the fuel system pressure. Remove the fuel filler cap and disconnect the fuel pump relay from the power distribution center, which is located in the engine compartment. The relays should be identified under the cover. Start your engine and let it run until it dies. Crank the engine several times, then remove the key from the ignition. Reattach the fuel pump relay.

Now, you can proceed to disconnect the fuel lines. First, ensure you are wearing safety glasses to protect your eyes from any fuel spray. Identify the type of fitting on your fuel pump. It could be a single-tab, two-tab, or plastic ring type. For tabbed fittings, squeeze the tabs so that the lines can be pulled apart. If it is a single-tab fitting, the tab will need to be discarded and replaced. For a plastic ring type fitting, loosen it by pushing in the locking ring.

Once the fittings are loosened, you can carefully pull the fuel lines apart. If you are dealing with a quick-release fitting, you may need to pinch the green tabs together and pull the fitting off the metal line. Be cautious, as this area can be difficult to access and may require some force to release. Practice on the rear quick-connect first to get a feel for how they work.

After disconnecting the fuel lines, you will need to clean up any spilled fuel with rags. Be sure to dispose of the rags safely, as they will be soaked with flammable fuel. Now you can proceed with the rest of your repair or maintenance work on the fuel system. Remember to exercise caution and avoid any open flames or sparks during the process.

It is always recommended to refer to your vehicle's repair manual for specific instructions and safety precautions when working on any part of your vehicle's fuel system.

Relieving fuel system pressure

To relieve the fuel system pressure on a 2000 Dodge Intrepid, follow these steps:

Firstly, take out the fuel filler cap. Then, disconnect the fuel pump relay from the power distribution centre, which is located in the engine compartment. You should be able to identify the relays under the cover of the power distribution centre.

Next, start your engine and leave it running until it dies. Crank the engine several times, then remove the key from the ignition. Attach the fuel pump relay back into the power distribution centre.

Finally, remove the negative battery cable from the remote ground terminal, which is located on the right fender in the engine compartment. Use a wrench to remove the retaining bolt, then pull out the cable.

Replacing the fuel pump

The fuel pump in your 2000 Dodge Intrepid pressurizes the gasoline in the car, allowing the fuel injectors to supply the engine with fuel. Here is a step-by-step guide to replacing the fuel pump:

Relieving the Fuel System Pressure:

• Remove the fuel filler cap.
• Disconnect the fuel pump relay from the power distribution center in the engine compartment. The relays should be identified under the cover.
• Start the engine and let it run until it dies. Crank the engine several times, then remove the key from the ignition.
• Reattach the fuel pump relay to the power distribution center.
• Disconnect the negative battery cable from the remote ground terminal on the right fender in the engine compartment. Use a wrench to loosen the retaining bolt, then pull out the cable.

Removing the Fuel Pump:

• Detach the fuel tank from your vehicle. The fuel pump module is located on the fuel tank.
• Remove the fuel lines and electrical connectors from the fuel pump module. This will depend on the type of fitting:

• For single-tab, two-tab, or plastic ring type fittings, squeeze the tabs to loosen them, then pull the lines apart. For single-tab fittings, the tab must be discarded and replaced.
• For plastic ring-type fittings, loosen by pushing in the locking ring.

• Loosen the module locknut by turning it counterclockwise with large channel lock pliers.
• Lift the fuel pump module out of the tank at an angle, being careful not to break the fuel level sending float unit. Clean any spilled fuel with rags.
• Place the removed module in a container or drain pan.
• Replace the seal where the fuel pump module sits on the fuel tank. Wipe down the tank-sealing surface with rags.

Installing the New Fuel Pump:

• Insert the new fuel pump module, lining up the tabs under the module with the notches on the fuel tank.
• Tighten the fuel pump module locknut to about 40 ft-lbs, either by hand or with channel lock pliers.
• Reattach the electrical connections and fuel lines to the new fuel pump module.
• Reinstall the fuel tank.
• Reconnect the negative battery cable to the stud and tighten the bolt with a wrench.
• Put the fuel filler cap back on.

Your 2000 Dodge Intrepid is now ready to hit the road again!

Sourcing parts

When sourcing parts for your 2000 Dodge Intrepid, it is important to consider the specific fuel line issue you are addressing, as different problems may require different parts.

If you are dealing with a leaking fuel line, as described in some of the forum posts, you may need to replace the entire fuel line or just a section of it. Some people have suggested splicing in a new piece of high-pressure fuel-grade rubber hose secured with clamps, which can be purchased from auto parts stores. Others have recommended buying the factory part, which may cost around $50.

If you are experiencing issues with the fuel pump connector, as mentioned in another forum post, you may need to replace the fuel pump module assembly. This part can be purchased from various manufacturers, including Delphi, Airtex, Carter, and Bosch, among others.

Additionally, if you are having trouble finding the correct fuel line or connector, you could try searching salvage yards or wreckers for a used part.

It is also worth noting that some auto parts stores may carry fuel lines and connectors specific to the Dodge Intrepid, so it may be worth contacting them directly to inquire about availability.

Finally, when sourcing parts, it is important to prioritize quality and compatibility with your vehicle to ensure optimal performance and safety.

Frequently asked questions