Repair Procedure

To install electric fuel pump, regulator, and fuel reservoir.

A. Engine Compartment Wiring Harness PN 4304992

1. Disconnect the battery.

^ Manual Transmission Vehicles - remove clutch cable bracket at left shock tower.

^ Automatic Transmission Vehicles - remove shift cable bracket (if so equipped) located at the left shock tower.

2. Remove engine side of bulkhead connector. Depress fingers of instrument panel half of bulkhead connector and push connector back through hole into passenger compartment.

FIGURE 1-A - UNDER HOOD WIRING:

3. Route engine compartment overlay harness, PN 4304992, across the cowl and down right fender shield to coil. Secure to main engine harness (on vehicles with harness routing as shown in Figure 1-A) with seven tie wraps, PN 6015756, evenly spaced (Figure 1-A). On vehicles where main harness routing is different than in Figure 1-A, tie wrap overlay harness to convoluted hose harness.

FIGURE 1-B:

4. Install the eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B.

FIGURE 1-C:

5. Remove black with red tracer wire (1983 K-CV and E-ET vehicles) or a gray with red tracer wire (1984-1985 vehicles) from cavity #34 of the engine side of the bulkhead connector (if so equipped) and tape back to main engine harness. Insert the bare terminal of the engine compartment overlay harness, PN 4304992, into cavity #34 of the engine side of the bulkhead connector (Figure 1-C).
B. Instrument Panel Harness PN 4209344, 4331800 (1985 only), 4331801

1. Remove left side cowl kick panel.

2. Remove fuse access panel. Remove the fuse block from its mounting location under the access panel near the steering column.

FIGURE 2-D:

3. Remove the following wires from the instrument panel side of the bulkhead connector (Figure 2-D):

a. Yellow wire from cavity #9.

b. Black/red or gray/red from cavity #34 (if so equipped).

FIGURE 2-A - INSTRUMENT PANEL WIRING:

Install the yellow wire just removed from bulkhead connector into the loose natural colored 1-way connector supplied in the instrument panel overlay harness, PN 4331801. If the vehicle was equipped with a black/red or gray/red wire from cavity #34, tape back to main instrument panel harness (Figure 2-A).

FIGURE 2-D:

4. Insert two bare terminals on instrument panel overlay harness, PN 4331801, into the instrument panel side of the bulkhead connector as shown in Figure 2-D and outlined below:

a. Yellow wire into cavity #9.

b. Gray with black tracer wire into cavity #34.

FIGURE 2-A - INSTRUMENT PANEL WIRING:

5. Connect the natural colored 1-way connector (on overlay harness, PN 4331801) to the loose natural colored 1-way connector that was installed on the wire removed from cavity #9 of the instrument panel side of the bulkhead connector in Step 3 (Figure 2-A).

6. Route instrument panel overlay harness, PN 4331801, along the main instrument panel wiring harness and secure with three tie wraps, PN 6015756, as shown in Figure 2-A.

FIGURE 2-C:

7. Insert the bare terminal (blue wire) from overlay harness, PN 4331801, into wiring jumper harness, PN 4209344. Install the bare terminal from the jumper harness, PN 4209344, into cavity #14 of the fuse block (Figure 2-C).

NOTE: SOME 1983-1984 VEHICLES MAY ALREADY BE EQUIPPED WITH JUMPER HARNESS, PN 4209344, IN CAVITY #14 OF THE FUSE BLOCK. IF SO, DISCARD JUMPER HARNESS, PN 4209344, SUPPLIED IN KIT.

SOME 1985 VEHICLES HAVE A WIRE ALREADY IN CAVITY #14. IF SO, REMOVE WIRE FROM CAVITY #14 AND CONNECT TO ACCESSORY FEED HARNESS, PN 4331800, SUPPLIED WITH KIT (TAPE CONNECTION OF BARE TERMINALS). INSTALL OPPOSITE END OF THE ACCESSORY FEED HARNESS, PN 4331800, INTO JUMPER HARNESS, PN 4209344 (FIGURE 2-C).
8. Install 10 amp fuse, PN 6101135, supplied in kit into cavity #14 of the fuse block.

NOTE: CERTAIN 1983-1985 VEHICLES HAVE A 6 AMP CIRCUIT BREAKER IN CAVITY #14 OF THE FUSE BLOCK. LEAVE THE CIRCUIT BREAKER IN CAVITY #14 AND DO NOT USE THE SUPPLIED 10 AMP FUSE.

9. Reinstall passenger compartment side of the bulkhead connector back into dash opening. Be sure it snaps in place.

10. Install the fuse block onto the mounting bracket.

FIGURE 2-A - INSTRUMENT PANEL WIRING:

11. Allow the black 2-way connector of harness, PN 4331801, to hang down along the left side cowl for mating with the body overlay harness (Figure 2-A).
12. Connect the overlay harness, PN 4331801, ground terminal to the instrument panel ground stud (located behind the fuse block) and secure with the supplied nut, PN 6023201 (Figure 2-A).

FIGURE 2-B - TYPICAL CONTROL MODULE MOUNTING:

13. Connect the control module, PN 5226640, to the natural colored 8-way connector on overlay harness, PN 4331801. Secure the module to tbe instrument panel main wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-B).

14. Reinstall engine side of bulkhead connector and torque to 40 inch pounds. Reinstall clutch or shift cable bracket (if so equipped).
C. Body Harnesses, PN 4331122, 4331855

1. Remove the left side sill scuff plate and rear seat upper and lower cushions. Remove the spare tire.

2. The existing wiring going through floor grommet to tank will not be used. Remove existing harness at floor grommet and locator clip on V support. Route old harness down to area under rear seat cushion. Spot tape harness to V support and to floor panel so wiring does not rattle. The old harness will be covered by the rear seat cushion when reassembled.

FIGURE 3-A:

3. Install sending unit jumper harness, PN 4331122, by feeding the black 5-way connector through tbe vacated grommet hole. Make sure grommet on new harness is fully seated in body hole (Figure 3-A).

4. Route the overlay harness, PN 4331855, along the left side rear wheel housing and along main body harness, working toward instrument panel using the retainer clips indicated in Figure 3-A. Tape overlay harness to main harness as shown in Figure 3-A).

CAUTION: MAKE SURE THAT THE OVERLAY HARNESS WILL NOT BE PINCHED FROM THE SCUFF PLATE FASTENING SCREWS DURING REINSTALLATION.

FIGURE 3-D:

5. Finish routing the overlay harness along the deck lid side of the V support and insert the locator clip in the vacated locator hole (Figure 3-D).

FIGURE 3-C:

NOTE: THE LOCATOR CLIP ON THE OVERLAY HARNESS, PN 4331855, WILL NOT BE USED FOR THE WAGON APPLICATION. INSTEAD, USE THE LOCATOR CLIP ON SENDING UNIT HARNESS, PN 4331122 (FIGURE 3-C).

FIGURE 3-A:

6. Connect the black 6-way overlay body harness connector to the black 6-way sending unit jumper harness connector. Tape connection to the V support with a minimum of three tape wrappings around the V support. Refer to Figure 3-A for location of spot taping. (No spot taping is required for wagon models.)
7. Connect the overlay body harness ground terminal to the body ground selftapping screw as shown in figure 3-A. On models where no screw exists, install ground terminal by drilling 1/8" hole and add self-tapping screw, PN 6032114.

FIGURE 3-E - 25 WAY I/PANEL TO BODY CONN. (WIRE END):

FIGURE 3-F - (TERMINAL END OF WEDGE CONN.):

8. Remove the 3-way and 10-way wedge connectors from the 25-way instrument panel-to-body connector. Remove and tape back to main harness the following wires (Figures 3-E and 3-F):

a. Dark blue wire from cavity #7 of the 10-way wedge connector.

b. Light blue with black tracer wire from cavity #23 of the 3-way wedge connector (vehicles equipped with "Low Fuel Warning" only).

FIGURE 3-B:

9. Route the two bare terminals of the overlay harness, PN 4331855, behind the parking brake release cable to the retainer clip located near the 25-way instrument panel-to-body connector (Figure 3-B). Insert the dark blue wire into cavity #7 of 10-way connector and the light blue with black tracer wire into cavity #23 of 3-way connector.

FIGURE 3-F - (TERMINAL END OF WEDGE CONN.):

10. Insert the 3-way and 10-way wedge connectors into the 25-way instrument panelto-body connector and reinstall the 25-way connector (Figure 3-F).

FIGURE 3-A:

11. Install the black 2-way connector on the body overlay harness, PN 4331855, to the black 2-way connector on the instrument panel overlay harness, PN 4331801 (Figure 3-A).

12. Reinstall the left side sill scuff plate, left side cowl kick panel, spare tire, and upper and lower rear seat cushions.

FIGURE 4 - SOLENOID COVER:

D. Engine Compartment

1. If vehicle is equipped with solenoid and plastic cover at right shock tower, remove cover and rework the plastic cover by cutting off one end as shown in Figure 4.

FIGURE 5 - DRILLING TEMPLATE PRESSURE REGULATOR BRACKET:

FIGURE 6 - FUEL RESERVOIR AND PRESSURE REGULATOR CONNECTIONS:

2. To mount the pressure regulator, tape the pressure regulator bracket template, PN 4275240, to the right side shock tower as shown in Figure 5. (Set aside solenoid when equipped to gain access.) Carefully locate the template against the fender shield and wheel well, being careful to keep the top side of the template level. Center punch three screw hole locations and drill three .165" diameter (#21 drill) holes. Attach the pressure regulator bracket, PN 4306973, with three self-tapping screws, PN 6031991, and tighten securely (Figure 6).

FIGURE 6 - FUEL RESERVOIR AND PRESSURE REGULATOR CONNECTIONS:

3. Attach the pressure regulator assembly, PN 4307233, to the mounting bracket with two self-tapping screws, PN 6033066 (Figure 6).
4. If applicable, reinstall the solenoid removed in Step 2.

FIGURE 7-A:

5. Remove the mechanical fuel pump, engine mounted fuel supply tubes, fuel filter, and engine mounted fuel return tube and hose. Discard these items (Figure 7-A).
6. Install the fuel pump pad cover, PN 4275325, with gasket, PN 5214680, and secure them with two screw and washer assemblies, PN 6500799. Torque to 16 foot pounds.

7. Remove the air cleaner crossover assembly. Remove air horn to crossover rubber gasket and discard the gasket.

FIGURE 7-B:

8. Install the fuel reservoir bracket and gasket assembly, PN 4306932 (Figure 7-B), over the carburetor air horn studs. Reinstall the air cleaner.
9. Attach the fuel reservoir/filter assembly, PN 4288337, to the bracket with two nuts, PN 6100047.

NOTE: IF VEHICLE IS ALREADY EQUIPPED WITH A FUEL RESERVOIR, IT MUST BE REMOVED AND REPLACED WITH FUEL RESERVOIR/FILTER PN 4288337 SUPPLIED.

FIGURE 6 - FUEL RESERVOIR AND PRESSURE REGULATOR CONNECTIONS:

10. Connect 5/16" fuel supply hose, PN 4203837, from the chassis fuel line to the pressure regulator inlet (Figure 6) and clamp with hose clamp screw on the bottom. Use hose clamp, PN 6500651 and torque to 10 inch pounds.

11. Connect the 1/4" vapor return hose, PN 4203535, from the reservoir to the chassis vapor return line and secure with hose clamp, PN 6500650 (Figure 6). Torque to 10 inch pounds.

12. Connect fuel supply hose, PN 4203838, from the pressure regulator outlet to the reservoir inlet and secure with hose clamp, PN 6500651 (Figure 6). Torque to 10 inch pounds.

FIGURE 7-B:

13. Connect the hose on the reservoir outlet to the carburetor inlet and secure with hose clamp, PN 6500651 (Figure 7-B). Torque to 10 inch pounds.

14. If solenoid cover was removed in Step 1, reinstall the cover over the solenoid.
E. Underbody Component Installation

1. 1983 & 1984 Cars

Remove existing fuel tank and install the new fuel tank assembly following the service manual procedure. Use a new positioning pad, PN 4185506, and new insulator pads, PN 4185395 and 4279340. Use the new fuel tank straps, PN 4279175 and 4279174. Be sure to attach the fuel tank vent hose to the fuel tank before it is raised against the floor pan.
1985 Cars

Remove existing fuel gauge sending unit from the fuel tank and install the new gauge/pump unit, PN 4075431, along with a new gauge unit seal, PN 6031475, following the service manual procedure.

CAUTION: USE CARE WHEN INSTALLING NEW GAUGE/PUMP ASSEMBLY IN TANK SO AS NOT TO BEND OR DAMAGE THE NEW GAUGE/PUMP ASSEMBLY.

2. Connect the 5-pin terminal of the body wiring harness to the fuel tank gauge unit.

3. Reconnect battery.

FIGURE 9:

4. Type in Authorized Modification Label, PN 4275086, as shown in Figure 9 and attach near VECI label.
5. Inspect the entire installation for proper wire and hose routing. Start engine and inspect for leaks.

FIGURE 8:

Refer to Figure 8 for Electric Fuel Pump Wiring Diagram Schematic.
POLICY: Reimbursable within the provisions of the warranty

TIME ALLOWANCE:
Labor Operation No. 14-70-11-95...........................3.0 Hrs.

FAILURE CODE: AM - Authorized Modification