Repair Procedure
This procedure involves installation of an electric fuel pump, control module, and fuel reservoir.A. Engine Compartment Harness PN 4362295 and Jumper (dash) PN 4362558
1. Disconnect the battery.
FIGURE 1-A - ENGINE COMPARTMENT WIRING:
FIGURE 1-C - BULKHEAD CONNECTOR AS INSTALLED (ENGINE COMPARTMENT SIDE):
2. Find the drill dimple on the bulkhead located 1-3/8" above the engine compartment side of the bulkhead connector as shown in Figures 1-A and 1-C. Drill a 1" diameter hole from the engine side through the instrument panel side making sure there are no obstructions. Install wiring assembly, PN 4362558, from the instrument panel side to the engine compartment and seat grommet in the newly drilled hole.
FIGURE 1-A - ENGINE COMPARTMENT WIRING:
3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756.
Loop and tape excess wire of the overlay harness - Figure 1-A.
FIGURE 1-B:
4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B.
FIGURE 5:
5. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar Multi-Purpose Grease, PN 4318063, and snap terminal into insulator located on engine side of jumper wiring assembly, PN 4362558 (Figure 5).
NOTE: DISCONNECT FEMALE INSULATOR FROM MALE INSULATOR PRIOR TO INSERTION OF TERMINAL, AND BE SURE THAT WIRE OF ENGINE HARNESS MATES WITH SAME COLOR WIRE OF JUMPER.
FIGURE 5:
FIGURE 2-C - INSTRUMENT PANEL WIRING:
B. Instrument Panel Harness PN 4362284
1. Insert the two bare terminals from the instrument panel overlay harness, PN 4362284, into insulator located on the instrument panel side of jumper wiring assembly, PN 4362558, per Figures 2-C and 5.
NOTE: DISCONNECT MALE INSULATOR FROM FEMALE INSULATOR PRIOR TO INSERTION OF TERMINALS, AND BE SURE WIRES OF INSTRUMENT PANEL HARNESS MATE WITH SAME COLOR WIRES OF JUMPER, RECONNECT INSULATORS.
FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING):
2. Disconnect the arced grey 7-way ignition switch connectors and remove the yellow wire from the instrument panel side (Figure 2-B). Install the yellow wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284.
FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING):
FIGURE 2-C - INSTRUMENT PANEL WIRING:
FIGURE 2-D - TERMINAL END OF FUSE BLOCK:
Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C).
3. Replace the 5-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D).
FIGURE 2-C - INSTRUMENT PANEL WIRING:
4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C).
Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C).
5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C).
6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C).
FIGURE 2-E - TYPICAL CONTROL MODULE MOUNTING:
7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E).
C. In-Tank Fuel Pump Installation
1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank.
2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided.
3. Install existing gauge/pump wiring:
^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly.
^ Tape back existing yellow mold connector white wire (this wire will no longer be used).
^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly.
^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly.
CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE.
^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank.
4. Reinstall fuel tank to original position.
FIGURE 3-A:
FIGURE 3-B - BODY WIRING HARNESS:
D. Body Wiring Harness PN 4362286
1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A.
FIGURE 3-B - BODY WIRING HARNESS:
2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B.
NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH.
FIGURE 3-C:
3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead.
NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES.
FIGURE 3-C:
FIGURE 5:
4. Coat the bare blade terminal of the body harness, PN 4362286, liberally with Mopar Multi-Purpose Grease, PN 4318063, and snap terminal into insulator located on engine side of jumper wiring assembly PN 4362558 (Figures 3-C and 5).
NOTE: INSULATORS SHOULD BE DISCONNECTED FROM STEP A, 5. IF NOT, DISCONNECT FEMALE INSULATOR FROM MALE INSULATOR PRIOR TO INSERTION OF TERMINAL AND BE SURE THAT WIRE OF BODY HARNESS MATES WITH SAME COLOR WIRE OF JUMPER. RECONNECT INSULATORS.
FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER:
E. Engine Compartment Fuel Reservoir/Filter Installation
1. Using template PN 4418042 for 1986 4 x 2 models only, PN 4418412 for 1987 4 x 2 models only, or PN 4418013 for all 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two
(2) holes .290" diameter (L size drill).
FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION:
2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 105 inch pounds.
3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-toreservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2).
4. On 4 x 2 Models
a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose.
b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end.
c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6".
d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4".
e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end.
CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING.
f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end.
4. On 4 x 4 Models
a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end.
b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576.
c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B).
d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B).
FIGURE 6:
5. Tighten all hose clamps to 10 inch pounds.
6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 6 and attach near VECI label.
7. Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
Labor Operation No. All - 14-70-17-93 . . . . . . . . . . . 2.1 Hrs.
FAILURE CODE: AM - Authorized Modification