Repair Procedure
This procedure involves the installation of an electric fuel pump, control module, and fuel reservoir filter.A. Instrument Panel Overlay Harness PN 4362559
1. Remove instrument panel left lower trim panel, remove engine cover and disconnect the battery.
FIGURE 1-A - BULKHEAD CONNECTOR AS INSTALLED(ENGINE COMPARTMENT SIDE):
2. Mark and drill a 1" diameter hole located 1" to the driver's side of the bulkhead connector in the engine compartment (Figure 1-A). Drill from the engine compartment side through the instrument panel side making sure there are no obstructions.
3. Install instrument panel overlay harness, PN 4362559, from the instrument panel side to the engine compartment side and seat grommet in the newly drilled hole.
FIGURE 1-B:
FIGURE 6:
4. Secure the bare eyelet ground terminal (black wire) from instrument panel overlay harness, PN 4362559, with screw, PN 9414722, to the back of the brake bracket (Figures 1-B and 6).
NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW.
FIGURE 1-C - INSTRUMENT PANEL WIRING:
FIGURE 6:
5. Disconnect the arced grey 7-way ignition switch connectors and remove the yellow wire from the instrument panel side (Figure 1-C). Install this justremoved wire into the natural colored 1-way female connector supplied with the instrument panel overlay harness, PN 4362559 (Figure 6).
NOTE: DISCONNECT FEMALE INSULATOR FROM MALE INSULATOR PRIOR TO INSERTION OF TERMINAL.
FIGURE 6:
FIGURE 1-C - INSTRUMENT PANEL WIRING:
FIGURE 1-D - INSTRUMENT PANEL WIRING:
6. Install the bare terminal of the yellow wire from the instrument panel overlay harness, PN 4362559, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors and the ignition switch connectors (Figures 1-C, 1-D and 6).
FIGURE 1-E - TYPICAL CONTROL MODULE MOUNTING:
7. Connect the control (auto shut down) module, PN 5226640, to the natural colored 8-way connector from the instrument panel overlay harness, PN 4362559. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 1-E).
FIGURE 1-D - INSTRUMENT PANEL WIRING:
FIGURE 6:
8. a. If the vehicle does not have power windows and power locks, there will be a free standing block 3-way male connector as part of the main instrument panel harness located as shown in Figure 1-D. Plug this connector into the black 3-way female connector of the instrument panel overlay harness, PN 4362559 (Figures 1-D and 6). This connection must be made for the electric fuel pump to be operational. The black 3-way male connector located on the instrument panel overlay harness, PN 4362559, will not be connected under these conditions, and must be taped back to the overlay harness.
b. If the vehicle has power windows and power locks, the black 3-way male connector, which is part of the main instrument panel harness, will be connected to the black 3-way female connector of the wiring harness for the windows and locks. Disconnect these two black 3-way connectors and install the male connector of the main wiring harness to the black 3-way female connector of the instrument panel overlay harness, PN 4362559 (Figures 1-D and 6). Install the black 3-way female connector of the power windows and power locks wiring harness to the black 3-way male connector of the instrument panel overlay harness, PN 4362559 (Figures 1-D and 6).
9. Install the ignition switch protection relay, PN 4221570, to the instrument panel overlay harness, PN 4362559, and tape to harness (Figures 1-D and 6).
10. If the 78 amp alternator package, PN 4397615, is not required, then fold back the black and red ammeter leads (90~ molded connectors) and tape them to the instrument panel overlay harness, PN 4362559, as they will not be used. If the 78 amp alternator kit is required, refer to Section F which covers the installation.
11. Secure the instrument panel overlay harness, PN 4362559, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Replace the instrument panel left lower trim panel.
FIGURE 2-A:
B. Engine Compartment Harness PN 4362295
1. Install the bare eyelet terminal of the overlay harness, PN 4362295, to the negative terminal of the ignition coil (Figure 2-A).
FIGURE 2-B:
2. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 2-B).
FIGURE 2-C - ENGINE COMPARTMENT WIRING:
3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead area using the existing wiring clips and three tie wraps, PN 6015756 (Figure 2-C). Loop and tape any excess wire of the engine overlay harness.
FIGURE 2-C - ENGINE COMPARTMENT WIRING:
FIGURE 6:
4. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar Multi-Purpose Grease, PN 4318063, and snap into black 2- way female connector located on engine side of the instrument panel overlay harness, PN 4362559 (Figures 2-C and 6).
NOTE: DISCONNECT FEMALE CONNECTOR FROM MALE CONNECTOR PRIOR TO INSERTION OF TERMINAL, AND BE SURE THAT BLACK WIRE OF ENGINE HARNESS MATES WITH BLACK WIRE OF INSTRUMENT PANEL OVERLAY HARNESS.
5. If the 78 amp alternator package, PN 4397615, is not required, then tape the red and black wires leading into the red connectors back to the main engine wiring harness. If the 78 amp alternator kit is required, then refer to Section F which explains the installation.
C. In-Tank Fuel Pump Installation
1. Remove the fuel tank gauge unit from the fuel tank per 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. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 35 gallon tank gauge/pump unit), and torque ground screw to 35 inch pounds.
CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT.
FIGURE 3-A - 35 GALLON TANK:
FIGURE 3-B - 22 GALLON TANK:
Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (Figure 3-A or 3-B).
Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only.
NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 35 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS, PN 4362293, WILL NOT BE USED.
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 4362293, to assure wiring is not pinched when reinstalling fuel tank.
4. Reinstall fuel tank to original position.
FIGURE 3-C - 35 GALLON TANK:
FIGURE 3-F - BODY WIRING:
D. Body Wiring Harness PN 4362293
1. Vehicles With 35 Gallon Tank
Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places.
FIGURE 3-D - 22 GALLON TANK:
FIGURE 3-F - BODY WIRING:
Vehicles With 22 Gallon Tank
Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places.
NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 35 OR 22 GALLON TANK.
FIGURE 3-F - BODY WIRING:
2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines.
NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA. TIE WRAP IN FOUR (4) PLACES (FIGURE 3-E).
3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists, loop and tie wrap in two (2) places and install into existing clip (Figure 3-F).
FIGURE 3-F - BODY WIRING:
FIGURE 6:
4. Coat the bare blade terminal of the body harness, PN 4362293, liberally with Mopar Multi-Purpose Grease, PN 4318063, and snap into the black 2-way female connector located on the engine side of the instrument panel overlay harness, PN 4362559 (Figures 3-F and 6).
NOTE: CONNECTORS SHOULD BE SEPARATED FROM STEP B. 4. IF NOT, DISCONNECT FEMALE INSULATOR FROM MALE INSULATOR PRIOR TO INSERTION OF TERMINAL AND BE SURE THAT DARK GREEN WIRE OF BODY HARNESS MATES WITH DARK GREEN WIRE OF INSTRUMENT PANEL OVERLAY HARNESS. RECONNECT CONNECTORS.
FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER:
E. Engine Compartment Fuel Reservoir/Filter Installation
1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) - (Figure 4-A).
FIGURE 4-B:
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 inch pounds.
NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR.
3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B).
4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with hose clamp, PN 6500650, at each end.
5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576.
6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve, PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple and clamp with hose clamp, PN 6500651, at each end (Figure 4-B).
7. 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 hose clamp, PN 6500651, at each end (Figure 4-B).
8. Tighten all hose clamps to 10 inch pounds.
9. For all models except those with dual air conditioning units, without electrically heated rear window defroster, and with the 60 amp alternator:
Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. Reinstall engine cover.
F. Vehicles Equipped With Dual Air Conditioning, Without Electrically Heated Rear Window Defroster, and With the 60 AMP Alternator Must Use the 78 AMP Alternator Package, PN 4397615
NOTE: IF VEHICLE CONTAINS THE 114 AMP ALTERNATOR, DO NOT USE THIS KIT OR MAKE ANY CHANGES IN THIS AREA.
FIGURE 5-A:
1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 5-A).
2. Remove the instrument panel hood and pull out the instrument panel cluster.
FIGURE 7 - PRINTED CIRCUIT BOARD CONNECTOR:
3. Locate the red and black right angle molded connectors which are part of the instrument panel overlay harness, PN 4362559, and install onto the ammeter studs which exist on the back of the printed circuit board (Figure 7).
a. Red mold and wire to top stud.
b. Black mold and wire to bottom stud.
4. Locate the 8-way printed circuit board connector and cut the following two wires (Figure 7).
a. Red wire from cavity #2.
b. Black wire from cavity #1.
5. Tape the end of each severed wire, fold the wires back, and tape them to the main instrument panel harness to prevent shorting. Replace instrument panel cluster and instrument panel hood.
FIGURE 5-C - 78 AMP ALTERNATOR WIRING:
6. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 5-C). Cut the wire leaving approximately 3" of wire extending out of the main harness. Tape the end of the lead thoroughly; then fold and tape the lead back against the main harness to prevent shorting.
7. Remove the 60 amp alternator assembly and install the 78 amp alternator assembly complete, PN 4111204, per the service manual alternator replacement procedure.
FIGURE 5-A:
FIGURE 5-C - 78 AMP ALTERNATOR WIRING:
8. Beginning at the bulkhead area, route and connect the alternator overlay wiring harness, PN 4362343 (Figure 5-A). Use the existing main engine wiring harness clips and three tie wraps, PN 6015756 (Figure 5-C and view in circle of Figure 5- A).
FIGURE 6:
FIGURE 5-B:
9. Locate the two bare terminals from the alternator overlay wiring harness, PN 4362343, and snap into the red 2-way female connector of the instrument panel overlay harness, PN 4362559 (Figures 5-B and 6). Remember to disconnect female connector from male connector to insertion of terminals.
CAUTION: THE RED WIRE LABELED (TAGGED) "BLACK" ON ALTERNATOR OVERLAY WIRING HARNESS, PN 4362343, IS A BLACK WIRE. LIKEWISE, THE BLACK WIRE LABELED (TAGGED) "RED" IS A RED WIRE. INSTALL THESE WIRES BASED ON THEIR LABELS AND NOT THEIR ACTUAL COLORS. INCORRECT WIRING WILL CAUSE THE AMMETER TO INDICATE DISCHARGING WHEN THE SYSTEM IS ACTUALLY CHARGING AND VICE VERSE. RECONNECT CONNECTORS.
FIGURE 5-C - 78 AMP ALTERNATOR WIRING:
10. Install the alternator output terminal of the alternator overlay wiring harness, PN 4362343, to the newly installed 78 amp alternator using the existing retaining nut (Figure 5-C).
FIGURE 5-A:
11. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring harness, PN 4362343 (shown in view in circle of Figure 5-A).
12. The bulkhead connector gasket, PN 4055399, which is included in the 78 amp alternator kit, PN 4397615, will not be used in this application.
13. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks and overall installation integrity. Reinstall engine cover.
FIGURE 8:
14. Type Authorized Modification Label, PN 4275086, as shown in Figure 8 and attach near VECI label.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
Labor Operation No. 14-70-17-94 2.5 Hrs.
14-70-17-61 0.7 Hrs.
Optional Equipment - Alternator Package/Vehicles Equipped With Auxiliary A/C and Without Electrically Heated Rear Window Defroster
14-70-17-62 0.3 Hrs.
Jumper Harness Package/Vehicles Without Auxiliary A/C and/or Heater
14-70-17-63 0.4 Hrs.
Relay Harness Package/Vehicles With Auxiliary A/C and/or Heater Without Power Windows
FAILURE CODE: AM - Authorized Modification