Mopar 5096149AA Fuel Pump/Level Module Kit

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Reinstall the assembly and tighten the locknut securely.

The fuel level sending unit is secured to the fuel pump housing by a pair of mounting rails on the side of the housing. To remove the sending unit from these two rails you must disengage a pair of locking lugs, located on the underside of the sending unit, that can only be disengaged from the mounting rails by aligning them with the cutouts in the rails. Using an awl or a small screwdriver, carefully lever the lug on the fuel level sending unit toward the area between the two mounting rails until it disengages from the locking lug on the upper rail. Then slide the sending unit to the left until the lugs on the underside of the sending unit are aligned with the cutouts in the mounting rails and lift off the sending unit.

Depress the release tab and disconnect the electrical connector from the underside of the fuel pump/fuel pressure regulator/fuel level sending unit assembly. Remove the wedge lock from the electrical connector. Using a special terminal removal tool or a suitable substitute, disengage each terminal from the electrical connector and pull out the wire and terminal from the backside of the connector.

If you suspect insufficient fuel delivery, check the following items first: Check the battery and make sure it's fully charged. On 2003 models, check the fuel filter for obstructions. Inspect the fuel line, hoses, and quick-connect fittings to verify there are no leaks. Verify that the fuel pump actually runs by listening for the sound of the pump operating. If the fuel pump makes no sound, check the fuel pump electrical circuit. Relieve the fuel system pressure. Use a fuel pressure gauge, hose, and adapter to tee into the fuel system. Disconnect the quick-connect fitting at the connection between the fuel delivery hose and the fuel rail. Tee in the fuel pressure gauge between the fuel delivery hose and the fuel rail. Start the engine and let it idle, checking that the fuel pressure is within the operating range. If the fuel pressure is higher than specified, replace the fuel pressure regulator. If the fuel pressure is lower than specified, inspect the fuel delivery lines and hoses for obstructions or leaks. If everything is in good shape, inspect the fuel pump inlet strainer for restrictions. If all components are okay, replace the fuel pump. After testing, relieve the fuel pressure, remove the fuel pressure gauge, and install the cap on the test port. If the fuel pump does not turn on, check the fuel pump fuse and relay. If the fuse and relay are good but the fuel pump still doesn't operate, inspect the fuel pump circuit.

Start by relieving the system fuel pressure and disconnecting the negative battery terminal.