Chrysler 5136022AG Fuel Pump Module/Level Unit

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Relieve fuel system pressure. Disconnect cable from negative battery terminal. Drain fuel tank to under 5/8-full. Remove rear seat cushion. Pull back foam pad covering fuel pump/fuel level sensor module. Pull off plastic access cover. Disconnect electrical connector from terminal on top of fuel pump/fuel level sensor module. Clean area surrounding mounting flange. Tap lock-ring counterclockwise with hammer and brass drift. Note square tab on edge of mounting flange. Disconnect two electrical connectors for fuel level sensors and fuel pump. Disconnect fuel supply line fitting from outlet pipe. Disconnect two return lines from fuel pump module. Lift up mounting flange and remove fuel filter/fuel pressure regulator/fuel level sensor module.

A fuel pump/fuel level sensor module, also known as the main fuel pump module, is located in the left compartment of the fuel tank. It includes the fuel pump inlet strainer, pump, fuel level sensor, and fuel pressure regulator. The module is removed as a complete assembly, and most replacement modules come with all these components. The auxiliary fuel pump module is located in the right side of the fuel tank and includes the main fuel filter and fuel pressure regulator. On earlier models, the fuel pressure regulator can be replaced separately, but on later models, neither component can be replaced separately. To remove the fuel pump/fuel level sensor module, the fuel system pressure must be relieved, the negative battery terminal cable must be disconnected, and the fuel tank must be drained to under 5/8-full. The rear seat cushion is removed, and the foam pad covering the module is pulled back. The plastic access cover is carefully lifted off, and the electrical connector is disconnected. The area surrounding the mounting flange is cleaned, and the lock-ring is loosened and unscrewed. The module is lifted up, and the electrical connectors and fuel supply line fitting are disconnected. The residual fuel is drained, and the module is carefully removed from the fuel tank. The installation is the reverse of removal, and after installation, the fuel system is primed by turning the ignition switch to On without operating the starter.

To perform a fuel pressure test, relieve the fuel system pressure and connect a fuel pressure gauge to the fuel supply line. 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 or replace the fuel pressure regulator.

Start by removing the module. Then, carefully cut the wiring harness clip and disconnect the fuel level sensor wires. Loosen the two retaining clips and pull out the fuel level sensor. You can replace either the fuel level sensor unit or the fuel pump module.

Begin by relieving the fuel system pressure and disconnecting the cable from the negative battery terminal.

Remove the module and detach the fuel level sensor. Cut the wire ties and disconnect the ground wires. Remove the fuel level sensor. If you're only replacing the fuel pressure regulator, you're done. To remove the regulator from the fuel filter module, pull out the retaining clip. Check the condition of the regulator's O-rings. If you're replacing the fuel filter module, remove the ground ring and install it correctly in the new module. Finally, installation is the reverse of removal.

Start by removing the module. Carefully cut the wiring harness clip and disengage the fuel level sensor wires from the clip. Then, loosen the two retaining clips and pull the fuel level sensor out of the fuel pump module. After installation, turn the ignition switch to On to activate the fuel pump and build up fuel pressure in the fuel lines.

To access the fuel pump/fuel level sensor module:Remove the rear seat cushion.Pull back the foam pad covering the module.Pull off the plastic access cover.

To remove the fuel filter/fuel pressure regulator/fuel level sensor module:Lift up the mounting flange for the module.Carefully remove the module from the fuel tank, ensuring not to damage the electrical harness or fuel return lines.

Remove the module and detach the fuel level sensor. Cut the wire ties and disconnect the ground wires. Remove the fuel level sensor. If you're only replacing the fuel pressure regulator, you're done. To remove the regulator from the fuel filter module, pull out the retaining clip. Check the condition of the regulator's O-rings. If you're replacing the fuel filter module, remove the ground ring and install it correctly in the new module. Finally, installation is the reverse of removal.

The module includes the fuel pump inlet strainer, pump, fuel level sensor, and fuel pressure regulator.

Start by removing the module. Then, carefully cut the wiring harness clip and disconnect the fuel level sensor wires. Loosen the two retaining clips and pull out the fuel level sensor. You can replace either the fuel level sensor unit or the fuel pump module.

Start by removing the module. Carefully cut the wiring harness clip and disengage the fuel level sensor wires from the clip. Then, loosen the two retaining clips and pull the fuel level sensor out of the fuel pump module. After installation, turn the ignition switch to On to activate the fuel pump and build up fuel pressure in the fuel lines.

To perform a fuel pressure test, relieve the fuel system pressure and connect a fuel pressure gauge to the fuel supply line. 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 or replace the fuel pressure regulator.