Mopar RL004936AC Fuel Pump Module/Level Unit

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If there is suspicion of insufficient fuel delivery, inspect all fuel lines for leaks. Set the parking brake and have an assistant turn the ignition switch to the ON position while listening for the fuel pump sound. If the fuel pump is operating, proceed to the pressure check. If not, disconnect the fuel pump electrical connector and check for power at the fuel pump connector. If power is not available, check the fuel pump circuit, related fuses, fuel pump relay, and wiring. Check the ground circuit for continuity. If power and ground circuits are good but the fuel pump still does not operate, replace the fuel pump. Pressure check: Relieve the fuel pressure. Remove the cap from the fuel pressure test port on the fuel rail and attach a fuel pressure gauge. Start the engine and check the pressure on the gauge. If the pressure is not within specifications, check for a restriction in the fuel system if the pressure is lower than specified. If the pressure is higher than specified, replace the fuel pressure regulator.

Check the voltage and resistance from the fuel level sensor with a full tank of fuel. Check if the vehicle has a fuel pump access cover and remove it if present. If there is no access cover, the fuel tank must be lowered to gain access to the fuel pump module. Drill out the rivets on the rear cargo hold-down clamps and remove them. Fold the carpeting forward. Remove the access cover nuts and use a heat gun to apply heat to the cover, then carefully pry it up and remove it. With the ignition key in the On position, measure the voltage at the terminal coming out of the fuel pump module sensor signal wire and compare it to the specified values. If the voltage is not within specifications, disconnect the battery cable. Disconnect the electrical connector from the upper section of the fuel pump module. Connect an ohmmeter to the terminals on the upper section of the fuel pump module where the sensor signal and ground wires were connected. Measure the resistance and compare it to the specified values. If the resistance is not within specifications, remove the fuel pump module and check the resistance of the sensor out of the vehicle. Measure the resistance with the float in the down (Empty) position and compare it to the specified values. Then measure the resistance with the float in the up (Full) position and compare it to the specified values. If the fuel level sensor resistance is incorrect or does not change smoothly as the float travels from empty to full, replace the fuel level sensor assembly. To replace the fuel level sensor, remove the fuel pump module. Lift the plastic locking tab while sliding the sensor upward to remove it. The remaining installation steps are the reverse of removal.

The fuel pump module comprises an upper section containing the fuel pressure regulator and fuel pump check valve, and a lower section housing the electric fuel pump and fuel pick-up/inlet filter. The entire fuel pump module is replaced as a complete assembly.

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