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Repair Procedure




This repair involves installation of an electrical fuel pump and control module.

A. Engine Compartment Harness PN 4362295 and Jumper PN 4362558

1. Disconnect the battery.

2. Drill a 1-inch diameter hole as dimensioned in Figure 1-A, making sure there are no obstructions. The silencer material on the passenger compartment side will have to be cut away as needed. Apply Mopar Silicone Rubber Adhesive Sealant, PN 4318025, as shown in Figure 1-B to the grommet of wiring assembly, PN 4362558, and install it from the instrument panel side to the engine compartment and seat grommet into newly drilled hole.

3. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-C.



4. Route and secure the overlay harness, PN 4362295, along with existing headlamp-to-dash main wiring harness to the bulkhead connector using the existing wiring clips and 6 tie wraps, PN 6015756, as shown in Figure 1-D. Loop and tape any excess wire of the overlay harness as illustrated.



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, as shown in 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.

B. Instrument Panel Harness PN 4331718

1. Remove instrument panel steering column cover.

2. Insert 2 bare terminals from instrument panel overlay harness, PN 4331718, into black insulator located on the instrument panel side of jumper wire assembly, PN 4362558, per Figure 5.






3. Disconnect the 5-way ignition switch connector and remove the yellow wire as shown in Figures 2-A and 5. 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 4331718.

NOTE: YELLOW WIRE IN FEMALE CONNECTOR SHOULD LINE UP WITH YELLOW WIRE IN MALE CONNECTOR OF OVERLAY HARNESS, PN 4331718 (FIGURES 2-A AND 5).
Install the bare terminal yellow wire of the instrument panel overlay harness, PN 4331718, into the previously vacated cavity in the ignition switch connector (Figures 2-A and 5).

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 4331718). Install the bare terminal dark blue wire from overlay harness into previously vacated cavity in ignition switch connector (Figures 2-A and 5).

5. Reconnect the natural colored 2-way connectors supplied with the instrument panel overlay harness and reconnect the ignition switch connector.

6. Remove left kick panel as outlined in the service manual.



7. Secure bare eyelet ground terminal (black wire) from instrument panel overlay harness to the existing instrument panel ground, located at the left side cowl (Figure 2-B). Torque screw to 65 inch-pounds.

8. Reinstall left kick panel.

9. Connect the control (auto shut down) module, PN 5226640, to the white colored 8-way connector from the instrument panel overlay harness. Fasten module to main instrument panel wiring harness with tie wrap, PN 6015756, as illustrated in Figure 2-C. Keep instrument panel harness and module clear of any possible interferences.



10. Route instrument panel harness and secure by spot taping as shown in Figure 2-D.
C. In-Tank Fuel Pump Installation

1. Remove the fuel tank gauge sending unit per service manual procedure and discard.

2. Install the new seal, P/N 6031475, and new gauge/pump unit, PN 4075447, per the service manual procedure. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank.

3. Attach the red mold of body wiring harness, PN 4331719, onto the red stud on newly installed gauge pump unit, PN 4075447. Reinstall dark blue wire of original wire harness onto black stud on gauge/pump assembly, and gray wire onto ground blade.

CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE INDICATOR TO FAIL AND THE ELECTRIC FUEL PUMP TO BE INOPERATIVE.
NOTE: SET ASIDE THE REST OF BODY HARNESS, PN 4331719, TO ASSURE HARNESS WILL NOT BE PINCHED WHEN RAISING FUEL TANK INTO POSITION.

4. Reinstall fuel tank per the service manual procedure.



D. Body Wiring Harness PN 4331719

1. Route and secure the body wiring harness, PN 4331719, along the right rear crossmember to the left rail using two (2) tie wraps, PN 6015756 (Figure 3-A).

2. Continue routing the body wiring along the existing brake lines on the left frame rail. Secure with fifteen (15) tie wraps, PN 6015756, equally spaced as shown in Figure 3-A.



3. At the engine compartment, route and secure the body wiring harness to the speedometer cable using one (1) tie wrap, PN 6015756, and to the bulkhead wiring using one (1) tie wrap (Figure 1-D).



4. Coat the bare blade terminal of the body harness, PN 4331719, 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: INSULATORS SHOULD BE DISCONNECTED FROM STEP A, ITEM 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.
E. Fuel Filter Installation

1. Remove the fuel filter with hoses near the mechanical fuel pump and discard. Install the fuel filter supplied, PN 4071965, four (4) clamps, PN 6500651, inlet and outlet hoses, PN 4203215, and the return hose clamp, PN 6500650.



2. Type in Authorized Modification Label, PN 4275086, as shown in Figure 6 and attached near VECI label.
3. Connect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks.
POLICY: Reimbursable within the provisions of the warranty


TIME ALLOWANCE:
Labor Operation No. 14-70-17-92 . . . . . . . . . . 1.7 Hrs.


FAILURE CODE: AM - Authorized Modification
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