Repair Procedure

1. Remove rear seat cushion.

2. Remove three (3) screws attaching fuel pump access cover. (Do not remove cover.)





3. Rotate access cover to expose hole in floor pan for the left rear cover attaching screw.





4. Using a drill stop, carefully drill the left rear hole in floor pan to 7.5 mm (19/64 in.).

* NOTICE:
Check below hole first to prevent damage or puncture of other parts.





5. Debur hole, and install 5mm rivet nut (supplied in parts kit) in the hole using a rivet nut installation tool (Snap-On HP650M or equivalent) with a 5mm mandrel.

* NOTICE:
Make certain rivet nut is fully seated and compressed to ensure a good ground and a flat surface for proper seating of fuel pump access cover.

6. Reinstall fuel pump access cover with front and right rear screws only.





7. Assemble new connector repair harness from kit by connecting halves of C304.

8. Place C304 repair harness (6 pin with ground wire) next to existing C304 harness in vehicle. (Note: Female connector goes to fuel pump side, male connector and new ground wire goes to rear harness side.)





9. Attach new ground wire to body at fuel pump access cover (where rivet nut was installed) using 5mm machine screw and washer supplied in parts kit.

10. Determine where to cut old wiring. Allow sufficient working length to splice in the new connector repair harness.





* NOTICE:
Before cutting harness, check wire colors in existing harness and in repair harness. If colors do not match, retain old connectors for reference or use masking tape to identify individual wire locations to ensure proper connections. To avoid cross connections, cut and install only one connector repair harness at a time.

Verify ignition is off, and cut old harness on both sides of C304.





11. Untape existing harnesses approximately 1-1/2 inches, then strip insulation on wires far enough to allow crimping and soldering.

12. Ensure heat shrink tubing is installed on all individual wires on new connector repair harness.





13. Match wire colors, connect and crimp individual wires with butt connectors provided in parts kit, then solder each connection.





WARNING:
Do not use open flame soldering equipment near fuel tank.





14. Position heat shrink tubing over solder joints and shrink in place using a heat gun. Tubing is installed correctly when hot melt glue is visible at ends.

15. Repeat procedures 7, 8, 10, 11, 12, 13 and 14 for C305 (4 pin) connector repair harness.





16. Re-tape both repaired harness sections and position connectors directly behind fuel pump access cover.

17. Start engine, confirm proper fuel pump/sending unit operation.

18. Reinstall rear seat cushion.





19. Install SC013 campaign completion label onto left rear door in location indicated.