Chrysler R5101830AB Fuel Pump/Level Module Kit

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Inspect the fuel pump circuit.

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.

Reinstall the assembly and tighten the locknut securely.

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.

Check the battery and make sure it's fully charged, check the fuel filter for obstructions, inspect the fuel line, hoses, and quick-connect fittings to verify there are no leaks, and verify that the fuel pump actually runs by listening for the sound of the pump operating.

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.

Installation is the reverse of removal.

Reinstall the assembly and tighten the locknut securely.

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.

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.