Chrysler 68004936AC Fuel Pump Module Assembly-And Level Sensor Module

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All wheel drive (AWD) models have a saddle fuel tank configuration and have main and auxiliary fuel pumps. Each fuel pump has a sending unit. The auxiliary fuel pump contains the fuel pump reservoir, fuel pressure regulator and fuel filter. Relieve the fuel system pressure. Disconnect the negative battery cable from the remote ground terminal or battery. Remove the rear seat cushion and fuel pump module cover. On AWD models, remove main and auxiliary fuel pump module covers. Disconnect the fuel delivery line quick-connect fitting and on 2015 and later models, also disconnect the fuel vapor line from the fuel pump/fuel pressure regulator/Fuel Level Sensor assembly. Disconnect the electrical connector from the fuel pump/fuel pressure regulator/Fuel Level Sensor assembly. Before removing the fuel pump/fuel pressure regulator/Fuel Level Sensor assembly, make alignment marks on the assembly and the fuel tank (if marks don't already exist), to ensure the assembly will be correctly realigned when it's installed again. Using adjustable-joint pliers, loosen the lock ring that secures the fuel pump/fuel pressure regulator/Fuel Level Sensor assembly. Carefully lift the fuel pump/fuel pressure regulator/Fuel Level Sensor assembly from the fuel tank. Angle the module so that you don't bend the float arm of the Fuel Level Sensor or damage the fuel pump inlet strainer. If you're removing the auxiliary pump on an AWD model, raise the fuel pump module and disconnect the internal fuel line. While the pump is removed, inspect the pump inlet strainer. Make sure that it's not clogged or damaged. If the inlet strainer is dirty, try washing it in clean solvent. If it's still clogged, replace it. Installation is the reverse of removal. Line up the marks, and tighten the fuel pump module lock ring securely.

The auxiliary fuel pump contains the fuel pump reservoir, fuel pressure regulator and fuel filter.

To begin, remove the fuel pump/fuel pressure regulator/fuel level sending unit assembly.

AWD models have a saddle fuel tank configuration.

AWD models have a saddle fuel tank configuration.

Using a narrow electrical connector terminal tool, dislodge the sending unit terminals from the connector body and install the terminals of the new sending unit into the correct positions in the connector. Finally, the remaining steps for installation are the reverse of the removal process.

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 sending unit signal and ground wires were connected. Measure the resistance and compare it to the specified values.

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.

Start by removing the access cover nuts. Cut the seal with a knife blade or apply heat to the outer edge of the access cover using a heat gun. Carefully pry up on the cover to remove it. Clean the area around the fuel lines and upper section to prevent dirt from entering the fuel system. Disconnect the fuel lines and electrical connector from the upper module if needed. Mark the orientation of the module to the fuel tank before removal.