Page 1 of 9 Home Account Contact ALLDATA Log Out Help DAN GRIMWOOD DAN GRIMWOOD00002 Select Vehicle New TSBs Technician's Reference Component Search: OK 1985 Dodge Truck D 350 Pickup V8-360 5.9L VIN I Conversion Calculator Vehicle Level Powertrain Management Fuel Delivery and Air Induction Fuel Pressure Regulator Technical Service Bulletins All Technical Service Bulletins Fuel System - Engine Vapor Lock Repair Procedure Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 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 1-C - ENGINE COMPARTMENT WIRING

Page 2 of 9 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. 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). INSTRUMENT PANEL WIRING

Page 3 of 9 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). 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). INSTRUMENT PANEL WIRING 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).

Page 4 of 9 ^ 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. 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

Page 5 of 9 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. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER

Page 6 of 9 E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 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

Page 7 of 9 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 +/- 10 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-to-reservoir 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. FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 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.

Page 8 of 9 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. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 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). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION

Page 9 of 9 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect 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: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All........... 2.1 Hrs. 14-70-17-50 - Add with Carter..... 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification 2010 ALLDATA LLC. All rights reserved. Terms of Use