Jeep RL004936AC Fuel Pump Module/Level Unit

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The fuel pump module consists of an upper section containing the fuel pressure regulator and fuel pump check valve, and a lower section consisting of the electric fuel pump and the fuel pick-up/inlet filter. The fuel pump module is replaced as a complete assembly. Relieve the fuel system pressure. Disconnect the cable from the negative battery terminal. Check the vehicle to see if it is equipped with a fuel pump access cover, then remove it. Drill-out the rivets on the two rear-most cargo hold-down clamps and remove the clamps. Fold the carpeting forward. Remove the access cover nuts. Use a knife blade to cut the seal or use a heat gun to apply heat to the outer edge of the access cover, then carefully pry up on the cover and remove it. Clean the area surrounding the fuel lines and upper section of the fuel module to prevent dirt from entering the fuel system. Disconnect the fuel lines and electrical connector from the upper module, as necessary. Mark the orientation of the module to the fuel tank before removing the module. Using a pair of large pliers to turn the lockring, or using a hammer and a brass drift, tap on the lockring to turn it counterclockwise to remove the upper section of the fuel pump module from the tank. Carefully lift up the upper section, then secure the rubber gasket to prevent it from falling into the tank. Detach and secure the fuel lines and electrical connector from the bottom side of the upper section. Remove the upper section from the tank. Using a siphoning kit, siphon the all of the fuel through the upper module opening, into an approved gasoline container. Reach inside the tank and press and release the plastic lock while lifting the tab. Slide the lower section to the right side of the tank to release it from the two guides in the fuel tank. Remove the lower section of the fuel pump module. Installation is the reverse of removal with the following additions: Install the lower section into the fuel tank by sliding it to the left and pressing down on the locking tab. Always replace the upper section gasket with a new one. Position the notch on the upper section so that it faces the rear of the vehicle, then install it. If equipped, apply silicone sealant to the bottom of the fuel pump access cover. After positioning the carpet in place, install two new rivets to secure the cargo hold-down clamps.

Check voltage and resistance from fuel level sensor with full tank. Remove fuel pump access cover if present. Drill out rivets on cargo hold-down clamps and remove. Disconnect battery cable and electrical connector from upper section of fuel pump module. Measure voltage and resistance and compare to specified values. Replace fuel level sensor if resistance is incorrect.

If you suspect insufficient fuel delivery, Inspect fuel lines for leaks. Have assistant turn ignition switch to ON and listen for fuel pump sound. If operating, proceed to pressure check. If not, check power at fuel pump connector. Check fuel pump circuit, fuses, relay, wiring, and ground circuit. If power and ground good but fuel pump still not operating, replace fuel pump. Relieve fuel pressure, attach fuel pressure gauge, start engine, and check pressure. If not within specs, check for restriction if pressure lower than specified. If higher, replace fuel pressure regulator.

Check voltage and resistance from fuel level sensor with full tank. Remove fuel pump access cover if present. Drill out rivets on cargo hold-down clamps and remove. Disconnect battery cable and electrical connector from upper section of fuel pump module. Measure voltage and resistance and compare to specified values. Replace fuel level sensor if resistance is incorrect.

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.

The fuel pump module comprises an upper section containing the fuel pressure regulator and fuel pump check valve, and a lower section housing the electric fuel pump and fuel pick-up/inlet filter. The entire fuel pump module is replaced as a complete assembly.

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