Fuel Tank Wiring Harness Modification (G1475832): Repair
NOTE:
- Some components shown removed for clarity.
- Some variation in the illustrations may occur, but the essential information is always correct.
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- For additional information on correct wiring harness repair techniques, refer to Wiring Harness .
- Refer to: Battery Disconnect and Connect (General Procedures).
- Refer to: Fuel Pump and Sender Unit (Removal and Installation).
Refer to: Fuel Pump and Sender Unit (V6 S/C 3.0L Petrol, Removal and Installation).
Refer to: Fuel Pump and Sender Unit (V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and Installation).
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NOTE: Cut the wires as close as possible to the electrical connector.
- Install the female terminal to the wire, and using a suitable tool crimp the first stage.
- Install the wiring harness grommet to the terminal, and using a suitable tool, crimp the second stage.
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- Repeat steps 5 to 8 for the second wire.
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CAUTION: It is essential that the wires are installed in the correct orientation as shown. The lug must be positioned opposite to the connector release clip.
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CAUTION: Make sure that the wires are installed correctly by pulling the wires gently to make sure they are engaged.
- Secure the electrical terminals with the anti-backout.
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NOTE: Cut the wires as close as possible to the electrical connector.
- Following the procedure above for the female terminals, install the two male terminals to the wires.
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CAUTION:
- Make sure that the wires are installed to align with the corresponding coloured wire on the opposite connector.
- It is essential that the wires are installed in the correct orientation as shown.
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CAUTION: Make sure that the wires are installed correctly by pulling the wires gently to make sure they are engaged.
- Secure the electrical terminals with the anti-backout.
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CAUTION:
- The male connector is to be installed on the sender side.
- Make sure that the wires are installed to align with the corresponding coloured wire on the opposite connector.
- It is essential that the wires are installed in the correct orientation to the connectors.
- Using the procedure outlined above for the passive side sender, remove the wiring connectors from the active side sender and replace with the new connectors from the parts kit.
- Re-route the active side sender wires as shown.
- Refer to: Fuel Pump and Sender Unit (Removal and Installation).
Refer to: Fuel Pump and Sender Unit (V6 S/C 3.0L Petrol, Installation).
Refer to: Fuel Pump and Sender Unit (V8 5.0L Petrol/V8 S/C 5.0L Petrol, Installation).
- Refer to: Battery Disconnect and Connect (General Procedures).