Repair Procedure
A. Engine Compartment Wiring Harness - PN 4331935 & Diode Wiring Jumper PN 43319241. Disconnect the battery.
2. Remove the engine side of the bulkhead connector. Depress the fingers on the body side of the connector and push it through the hole into the passenger compartment.
FIGURE 1-A:
3. Install the bare eyelet terminal of the engine compartment overlay harness, PN 4331935, to the negative terminal of the ignition coil as shown in Figure 1-A.
CAUTION: MAKE SURE THAT THE WIRE END OF THE TERMINAL IS POINTING AWAY FROM THE COIL SECONDARY TOWER WHEN NUT IS TIGHTENED TO AVOID ARCING.
*Revised Part Number TSB 18-37-86 Revised December 8, 1986
FIGURE 1-B - ENGINE COMPARTMENT WIRING:
FIGURE 1-C - ENGINE COMPARTMENT WIRING:
4. Route the overlay harness along the existing headlamp-to-dash main harness from the coil forward to radiator cowl panel, then toward the left side of the engine compartment under fans and radiator as shown in Figure 1-B. Then route harness upward and toward the rear of the engine compartment to the bulkhead connector as shown in Figure 1-C. Pass it through the large retainer clip nearest the bulkhead connector. Secure the overlay harness by using existing wiring clips and six tie wraps, PN 6015756, as shown in Figures 1-B and 1-C.
FIGURE 1-D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE):
5. Coat the bare blade terminal of the overlay harness liberally with Mopar General Multi-Purpose Grease, PN 4318063, and snap into cavity #15 of the engine side of the bulkhead connector (Figure 1-D). Fill unsealed cavities above cavity #15 with Multi-Purpose Grease, PN 4318063.
FIGURE 7 - WIRING DIAGRAM:
6. Remove the large 5-way connector on the starter relay and extract the yellow wire (S-2 circuit - note position of wire in connector). On Diode Wire Jumper, PN 4331924, remove the loose insulator from the yellow with black tracer wire. Reset tang and snap the bare terminal of yellow wire (S-2 circuit) removed from the starter relay into the loose insulator from Diode Wire Jumper, PN 4331924. Mate male connector on Diode Wire Jumper, PN 4331924, with female connector now on yellow wire (S-2 circuit) from starter relay (Figure 7).
7. Insert bare female terminal wire (yellow with black tracer) of Diode Wire Jumper Harness, PN 4331924, into starter relay connector (same cavity from which S-2 yellow wire was extracted in Step 6, Figure 7).
FIGURE 2-A:
B. Instrument Panel Wiring Harness PN 4331574 (contains in-line fuse)
1. Remove the instrument panel steering column cover and lower silencer (optional) (Figure 2-A).
FIGURE 2-B - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE):
2. Insert two bare terminals from the instrument panel overlay harness, PN 4331574, into the following vacant cavities of the instrument panel side of the bulkhead connector (Figure 2-B).
a. Gray with black tracer wire into cavity #15.
b. Dark green wire into cavity #16.
FIGURE 2-C - INSTRUMENT PANEL WIRING:
FIGURE 7 - WIRING DIAGRAM:
3. Disconnect the 5-way ignition switch connector and remove the yellow wire (Figures 2-C - steering column may need to be lowered to gain access). Install the yellow wire just removed, into the top half of the natural colored 2-way female connector supplied with the instrument panel overlay harness, PN 4331574.
NOTE: YELLOW WIRE IN FEMALE CONNECTOR MUST LINE UP WITH YELLOW WIRE IN MALE CONNECTOR OF OVERLAY HARNESS, PN 4331574 (FIGURES 2-C AND 7).
Install the bare terminal yellow wire of the instrument panel overlay harness, PN 4331574, into the previously vacated cavity in the ignition switch connector (Figures 2-C and 7).
4. Remove the dark blue wire from the 5-way ignition switch connector and install into the bottom half of the natural colored 2-way female connector of overlay harness (opposite the dark blue wire in male half of overlay harness, PN 4331574). Install the bare terminal dark blue wire from overlay harness into previously vacated cavity in ignition switch connector (Figures 2-C and 7).
5. Reconnect the natural colored 2-way connectors supplied with the instrument panel overlay harness and reconnect the ignition switch connector.
FIGURE 2-A:
6. Remove the far right-hand screw from the lower reinforcement steering column support bracket. Secure bare eyelet ground terminal (black wire) from the instrument panel overlay harness, PN 4331574, to the steering column support bracket using screw, PN 9422247 (Figure 2-A). Tighten securely.
7. Connect the control module, PN 5226640, to the white 8-way connector from the instrument panel overlay harness.
FIGURE 2-D - INSTRUMENT PANEL WIRING:
FIGURE 2-E - TYPICAL CONTROL MODULE MOUNTING:
8. Route the instrument panel harness and module to keep them clear of any possible interferences. Spot tape the overlay harness to the main harness every six inches as shown in Figure 2-D. Secure the control module to the main harness with a tie wrap, PN 6015756, close to the bulkhead connector as shown in Figure 2-E.
FIGURE 2-A:
9. Replace the steering column lower silencer and cover (Figure 2-A).
C. In-Tank Fuel Gauge Pump Unit Assembly Installation
1. Refer to the service manual procedure for removing fuel tank sending unit.
2. Install seal, PN 6031475, on the new gauge/pump unit, PN 4075479*, (15 gallon tank) or 4075480* (20 gallon tank). Using extreme caution to protect the float and gauge assembly, install new gauge/pump unit in the fuel tank.
3. Refer to the service manual procedure for the balance of the installation of the fuel tank sending unit.
4. Install the 3-terminal fuel gauge connector to the gauge/pump unit.
D. Body Wiring Harness PN 4331724
1. Insert the mold of body harness, PN 4331724, onto the stud of the fuel tank gauge/pump unit.
*Revised Part Number TSB 18-37-86 Revised December 8, 1986
FIGURE 3-A:
2. Insert the "basket handle" type clip into the existing ring clip on rear crossmember. Route the harness along the rear crossmember to the left frame rail. Secure the harness using two tie wraps, PN 6015756 (Figure 3-A).
FIGURE 3-B - BODY WIRING:
3. Route the body harness, PN 4331724, along the existing brake lines on the left frame rail, working toward the engine compartment. Secure the harness with eight (8) tie wraps, PN 6015756, locating each tie wrap near the existing brake line clips (Figure 3-B).
FIGURE 1-D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE):
4. At the engine compartment route the harness through the speedometer cable clips to the bulkhead connector.
5. Coat the bare blade terminal of the body harness, PN 4331724, liberally with Mopar Multi-Purpose Grease, PN 4318063, and snap into cavity #16 of the engine side of the bulkhead connector (Figure 1-D). Fill unsealed cavities above cavity #16 with Multi-Purpose Grease, PN 4318063.
6. Reinstall instrument panel half, then engine compartment half of bulkhead connector. Torque to 40 inch pounds. 18-13-85-5-
FIGURE 4 - PRESSURE REGULATOR BRACKET INSTALLATION:
E. Engine Compartment Fuel Component Installation
1. On the right side of the dash panel mark the location of the pressure regulator bracket top attaching hole as shown in Figure 4. Center punch and drill a 1/8" diameter hole and attach pressure regulator bracket, PN 4306972, with selftapping screw, PN 6031991. (Position the bracket so its top surface is horizontal and tighten screw securely.) Drill 1/8" diameter holes in the center of the two lower bracket holes. Install the remaining two screws, PN 6031991, and tighten securely.
FIGURE 5-B - FUEL COMPONENT INSTALLATION:
2. Attach the pressure regulator assembly, PN 4307380, to the bracket, PN 4306972, with two self-tapping screws, PN 6033066, and tighten securely.
3. Remove and discard the mechanical fuel pump, engine mounted fuel supply tubes, fuel filter, engine mounted fuel return tube, fuel supply hose from the chassis line, and fuel return hose from the chassis line (Figure 5-A).
4. Install the fuel pump pad cover, PN 4275325, with gasket, PN 5214690, and secure them with two screw and washer assemblies, PN 6500799. Torque to 16 foot pounds.
5. Remove the air cleaner crossover assembly. Remove and discard the air horn to crossover rubber gasket.
FIGURE 5-A - FUEL COMPONENT INSTALLATION:
6. Install the fuel reservoir bracket and gasket assembly, PN 4306932, (Figure 5-B) over the carburetor air horn studs, then reinstall the air cleaner.
NOTE: BEFORE INSTALLING RADIATOR SIDE AIR CLEANER CROSSOVER WING NUT, SLIP BRAKE BOOSTER HOSE RETAINER CLIP, PN 6015682, OVER CARBURETOR AIR CLEANER STUD. (MIDDLE FINGER FACING RESERVOIR) INSTALL WING NUT AND ROUTE BRAKE BOOSTER HOSE IN CLIP, BENDING FINGERS OF CLIP AROUND HOSE TO HOLD IN PLACE (FIGURES 5-A AND 5-B).
FIGURE 6 - HOSE ROUTING & UNDERHOOD COMPONENT LOCATION:
7. Attach the fuel reservoir/filter assembly, PN 4288337, to the bracket with two nuts, PN 6100047.
8. Connect the 5/16" fuel supply hose assembly, PN 4203866, from the chassis fuel supply line to the pressure regulator inlet (Figure 6). Secure the hose with hose clamp, PN 6000651, and torque to 10 inch pounds.
9. Install fuel supply hose assembly, PN 4203837, from the pressure regulator outlet to the fuel reservoir inlet. Secure with hose clamp, PN 6500651, and torque to 10 inch pounds.
10. Install the vapor return hose assembly, PN 4203860, from the reservoir return nipple to the chassis vapor return line. Secure with hose clamp, PN 6500650, and torque to 10 inch pounds.
11. Connect the hose on the reservoir outlet (bottom) to the carburetor inlet. Secure with hose clamp, PN 6500651, and torque to 10 inch pounds.
12. Reconnect battery.
FIGURE 8:
13. Type Authorized Modification Label, PN 4274086, as shown in Figure 8 and attach near VECI label.
14. Check the pressure regulator, fuel reservoir, and hose clip for secure mounting. Check all wiring and fuel hoses for proper routing, making sure they are not contacting any sharp metal edges. Make sure clamps are tight and no sharp edges or clamp screws are contacting adjacent hoses or wires. Start the engine and check the entire system for fuel leaks.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
Labor Operation No. 14-70-17-91..........................2.4 Hrs.
FAILURE CODE: AM - Authorized Modification