Chrysler 5101830AA Fuel Pump/Level Module Kit

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To replace the fuel pump/fuel pressure regulator/Fuel Level Sensor, start by relieving the system fuel pressure and disconnecting the negative battery terminal. Then, remove the fuel tank and disconnect the fuel delivery line quick-connect fitting and electrical connector from the assembly. Before removing the assembly, make alignment marks on the mounting flange and fuel tank for correct realignment during installation. Loosen the locknut securing the assembly using a brass punch and hammer, and carefully lift it from the fuel tank, being mindful of the float arm and fuel pump inlet strainer. Inspect the inlet strainer and clean or replace if necessary. Finally, reinstall the assembly and tighten the locknut securely.

Check the battery, fuel filter, fuel line, hoses, and quick-connect fittings for leaks. Use a fuel pressure gauge to check the fuel pressure. If higher than specified, replace the fuel pressure regulator. If lower, inspect the fuel delivery lines and hoses. Inspect the fuel pump inlet strainer for restrictions. If all components are okay, replace the fuel pump. 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.

Remove the fuel tank cap and listen for the sound of the in-tank pump when the ignition key is turned to On. If the pump is not heard, check the fuses and then proceed to the following steps. Raise the rear of the vehicle and locate the wire harness to the fuel pump. Unplug the fuel pump electrical connector and use a test light to check for voltage to the pump in the On and Start positions of the key. If there is voltage, replace the pump or trace the wires for any open or short circuit. If the pump still doesn't work, have the vehicle checked by a professional. Relieve the fuel pressure and connect a fuel pressure gauge to the fuel inlet hose. Start the engine and record the fuel pressure. If the pressure is below specifications, check for a plugged or restricted fuel filter or line. If the pressure is still low, pinch the return line and if the pressure increases, replace the fuel pressure regulator. If there is no change in pressure, check for a plugged fuel pump sock filter or a defective fuel pump. If the fuel pressure is above specifications, disconnect the primary wires from the ignition coil and remove the return hose. Connect a short section of hose and direct it into a fuel container. Have an assistant crank the engine and check for a plugged return line. If the pressure is now correct, the problem is a restricted return line. Finally, detach the vacuum hose from the fuel pressure regulator and observe the gauge for an increase in pressure. If there is no increase, replace the fuel pressure regulator.

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.

Installation is the reverse of removal.

Reinstall the assembly and tighten the locknut securely.

Make alignment marks on the mounting flange and fuel tank for correct realignment during installation.

Check the fuel pump fuse and relay.

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.

Inspect the inlet strainer and clean or replace if necessary.

Use a hammer and a BRASS punch to remove the fuel pump lock ring in a counterclockwise direction. Lift the fuel pump and O-ring out of the tank. Clean the sealing area of the tank and install a new O-ring. Inspect the fuel inlet sock filter for damage and contamination, replacing it if necessary. Place the fuel pump in position, install the locking ring, and use a hammer and a BRASS punch to secure it. Finally, install the fuel tank.

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.