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FORE/Arrington Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
NOTE: BEFORE STARTING IT IS BEST TO HAVE THE GAS TANK LEVELBETWEEN 3/8 AND 1/2 OF A TANK OF GAS ANY MORE THEN THAT AND WHEN THE OEM FUEL HAT IS REMOVED YOU WILL HAVE GAS RUNNING OUT OF THE TANK
Do not do this in a totally enclosed area
Please read these instructions before starting
A separate Document (Harness Install Pictures ") has pictures of the Harness and the install. These pictures will be referred to during the install process. There are 6 pictures of the Harness & 73 of the Install Process
First let's look at what tools are needed;
1.A 10 mm Wrench or 3/8 inch Drive Ratchet and 10mm Socket
2. An 8 to 16 oz. hammer ( to install the Black Plastic retainer )
3.A 18mm Wrench or 1/2 inch Drive Ratchet and 18mm Socket
4.A Scissors (to cutthin Black foam covering & electrical Tape)
5.Wire cutters & small pliers
6.Wire stripper ( to strip #14 thru #20 Wire )
7.Soldering Iron or a small Soldering Gun
8.Small pry bar ( Trim removal tool )
9. 1/4 inch drive 3 inch extension ( see install instructions Page # 9 Step # 3 )
10. Fuel Hat locking ring removal tool or a 5 Lb hammer & a 3/8 inch x 18 inch steel rod to remove the locking ring
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
This Harness comes with ALL the parts needed for the install except for the tools and the listed items on Page 3 that you need to supply . The install requires NO holes drilled is secured in place and is out of sight once installed
Items Supplied with The Harness
1.1 FORE /Arrington Fuel Hat Fuel Dual Fuel Pump Wire Harness
2.1 30/40 amp 5 Pin Automotive Relay ( installed on the Harness )
3. 1 ATC 25 Amp Fuse
4.10 8 inch Black Cable Ties
5.1 11 inch Black cable tie
6.10 Pieces of Al tape 6 inches Long by 2 inches wide
4.1 3/16 inch Black Plastic Push Retainer
7.1 12mm x 1.75 Metric Nut
8.1 2 inch by 4 inch piece of 100 grit sandpaper
9.1 # 10 flat washer
10.1 Wood Sanding Dowel ( sandpaper on both ends )
11. 1 Piece of 1/4 inch Split Wire Loom 14 inches long
12.1 Piece of 1/4 inch Split Wire Loom 24 inches long
13. Help via E-MAIL or a Phone Call if needed
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
Now for Additional Items not supplied with the Harness
1.Solder
2. Electrical Tape
3. A Fan to remove gas fumes
Let's Take a close look at the Harness ( Pictures 1, 2, 3, 4, 5, & 6 )
Installing this Harness Does Not require drilling any holes It is held in place on existing studs for the Positive lead & the Negative Lead , Cable ties, AL tape and one "Black Plastic Push Retainer" on an existing "Push Stud"
- Before we start taking things apart and removing parts from the car let's take a look at the wire harness. And Verify the following:
- First that the 4 Pin External Connector on the FORE Fuel Hat has the 2 Large RED Pump Power Leads go to the 4 Pin Connector Pins A & B and the 2 Large Black Power Leads go to the4 Pin Connector Pins C & D
- Second that the 3 Pin Connector on the FORE Fuel Hat has the Small Yellow wire going to Pin A a Small Black Wire going to Pin B and a Small Blue wire going to Pin C
- This is the FORE/Arrington Fuel Hat Wire Harness Complete ( Picture #1 )
- 18 inches from the relay toward the Positive ring terminal is a 1/2 inch Ring terminal that will be bolted in place on an existing stud. This is the Harness Ground ( Picture #2 )
- Close to that end is the Power Relay that will be held in place on a "Push Stud" with a Washer & a Black 3/16 inch Plastic Retainer ( Picture #3 )
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
- On the far end of the Harness is a ATC Fuse type Fuse Holder and a Power Terminal that connect to the rear fuse box 1/4 inch terminal ( Picture #4 )
- Branching off at the Relay is the Relay enable cable is a 2 Pin Connector that connects to the OEM wiring ( Picture #5 )
- The other branch Cable from the Relay goes to the Fuel Hat to Power up the Fuel Pumps ( Picture #6 )
- The Harness is protected and covered with Split Black Plastic Wire Loomor Electrical Tape
Hers is a best guess on Sections of the Process and Total Time
Park your car in a place where you can get at the trunk and the Pass. Door. Best guess is 30 minutes to remove everything necessary for the Harness install
30 minutes for Harness Prep Work
60 minutes for the Harness install
45 minutes to solder the 2 connectors
30 Minutes to remove the OEM Fuel Basket
45 minutes to finish the FORE/Arrington Fuel Hat internal wiring for the Fuel Level Transmitters
30 Minutes to install the FORE/Arrington Fuel Hat
30 minutes to finish the Connections and Start the Car with the "NEW" Fuel supply System
?? Drive around time to verify the Install
30 minutes to put the car back together
Total Time 5 1/2 + Hours So set aside at least 5 1/2+ Hours for the Install
TAKE YOUR TIME QUALITY IS JOB ONE
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
It's time to get Started ( let's get to it )
Looking at the Harness is done. The Car is parked, now it's time to take things apart that's always fun, and remove them ( here starts your 30 minutes )
1.Open the trunk and the Passenger door
2 Slide the passenger seat as far forward as it will go & tilt the passenger Seat as far forward as it will go ( Picture #7 )
3.Remove everything in the trunk and set aside ( Picture #8 )
4.Remove the Trunk Bottom Cover and set aside ( Picture #9 )
5.Remove the Spare tire ( Unscrew the plastic retainer ) and set it aside you can leave the jack in place ( Picture # 10 )
6. Using a 10 mm wrench Remove the Positive Battery Connection & insulate place a rag around the Battery cable connector( Picture 11,12 & 13)
7. Remove the Plastic cover on the Rear fuse Box push in on the tab on the end of the cover closest to the center of the trunk( Picture #14 )
8.Remove the lower Back Seat Pull up on the bottom edge 4 inches from the ends Its takes a little force and set aside ( Picture #15 & 16 )
9.Remove the Back Seat Back There are 5 18 mm Huts holding the Seat Back in place pull the Seat backs down ( both half's ) and using a 18mm wrench or 18 mm socket and Ratchet wrench Removethe 5 Nuts that hold the 2 seat half's in place. There are 2 nuts on the Driver's side 1 nut in the center left hand side and 2 nuts on the Passenger's side ( Pictures 17, 18, &19 )
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
10.The Seat half's are connected by a pin at the back & bottom ofthe Seat Back between the seat half's. Pull the Seat Back on the Pass. side forward lifting the SeatBackbracket off the studs, Passenger seat and center Studs and then pull on the Passenger Seat till itclearsthe pin. Remove the Passenger seatand set it aside outside the car . Pull the Drivers side Seat Back off theits Bracketand remove the Drivers Side Seat also set it aside. outside the car ( Picture 20 )
11. Follow the fender side cover on the Driver's seat side till where it meets the foam covering from under the back seat this foam covering extends into the trunk about 8 inches . 8 inches back from this junction and 1 inch up from the foam on the plastic fender cover is a Plastic "Push Pin". Use a small pry bar or trim removal tool remove this plastic "Push Pin" set it aside as you will reinstall later ( Pictures 21 & 22 )
12.Follow the fender side cover on the Passenger's seat side till where it meets the foam covering from under the back seat ( this foam covering extends into the trunk about 8 inches ). 8 inches back from this junction and 1 inch up from the foam on the plastic fender cover is a Plastic "Push Pin". Use a small pry bar or trim removal tool remove this plastic "Push Pin" set it aside as you will reinstall later ( Pictures 23 & 24 )
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
You are now done with what has to be removed now it's on to the Harness installPrerp Work ( how did you do on your 30 Minute Removal ??? )
Now let's start with some Harness install prep (we are almost ready to install )
Your 30 minute Harness Prep Work starts now
1.With scissors in hand cut the thin black foam covering that covers the bottom of the back seat and part way into the trunk alongside the drivers rear seat arm rest up to where the fender well starts Bottom of the incline continue cutting following the bottom of the fender well into the trunk till the foam covering is cut into 2 pieces ( Picture 25 & 26)
2.Pull back the thin black foam covering that extends from under the back seat and into the trunk pulling the thin black foam out from under the side Plastic fender covering on the Pass side only this is why you pulledout the plastic "PushPins" and pull it toward the front seat exposing the rear back seat back mountingstuds. On the driver's side pull the thin black foam covering back exposing the OEM Fuel Hat black plastic cover ( Pictures 27 , 28 & 29 )
3. Take your Wood sanding dowel that has a sanding disk on each end and slide it in a twisting motion over the 12mm x 1.75 mm stud that is at the front side of the trunk and to the Right of the trunkcenter located 12 inches from the right fender plastic cover.Use the 60 grit side first and finish with the 100 grit side Remove the paint ( 1 inch Dia. ) at the base of the stud. Usethe separate piece of sandpaper provided to remove any remaining paint in the 1 inch Dia. that the Woodsanding dowel did not remove . this Stud is the Fuel Pump's ground and the pumps need a good ground connection ( Picture 30 & 31 )
Well How did you do on your 30 minute Harness Prep work ???
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
Harness install ( This starts your 1 hour install )
First off lets layout the harness in the general way it will be run. No need to be exact at this point
Lay the end of the Harness with the Power Relay at the back of the Fuel Hat Cover. Runthe Harness along the back side of the Mounting brackets toward thePassengers wheel plastic cover and then alongside the battery cable overthe trunk lip and back to the rear fuse Box ( Picture 32, 33, 34 & 35 )
We are going to now route, bolt, Install, cable tie and al tape the Harness in place from the power relay to the Rear Fuse Box
( it's about time for some positive progress )
1.Locate the 1/2 inch ground ring terminal place the terminal over the stud that you just sanded such that the wire end of the terminal faces toward the center of driver's side fender plastic cover and the Harness runs across the trunk following the back side of the seat mounting brackets. Take the 12mm x 1.75 serratedCassel nut and thread onto the stud making the nut hand tight. Holding the terminal in positiontighten the nut using a wrench this is the Harness Ground connection so make sure it is tight ( Picture 36, 37,38 )
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
2.Locate the power relay and the relay mounting hole. There is a "Push Stud" located 3 inches behind the right rear corner of the Black plastic Fuel Hat Cover. Place the power relay mounting hole over this stud place one #10 flat washer see your parts bag for this washer over the stud then place one Black plastic 3/16 inch retainer over the stud and tap with the hammer till the top of the black plastic retainer is even with the top of the stud. ( Pictures 39 & 40 )
3.Turn the power relay till it lines up with the rear fender rise with the relay harness end pointing toward the middle of the trunk fender well on the passenger side. Now take the 1/4 inch extension and using the recessed end and the hammer tap on top of the black plastic retainer till it is tight against the washer and the Relay is firmly in place ( Picture 41 & 42 )
4Tape The Harness in place using 2 pieces of supplied Al Tape ( Picture 43 & 44 )
5.Route the harness along the back side of the Seat brackets toward a plastic cable tray located on the passenger side of the car. Half way between the mounted ground ring terminal and the plastic cable tray is a bracket with a 3/8 inch hole in the center of the bracket toward the back edge Using a 8 inch black plastic cable tie secure the harness in place tying it to this bracket hole with the cable tie ( Picture 45 & 46 )
6.Tape the Harness in place with a supplied piece of Al Tape ( Picture 47 )
7.Rout the Harness over to the Battery Large RED Power Wire that runs from the Battery to the front of the car. Put a 90 Degree bend in the Harness routing the Harness alongside the Battery cable toward the back to the trunk Upper edge using the 11 inch cable tie to tie in Place ( Pictures 48 )
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
8.Tape the Harness in Place using a Supplied piece of Al Tape ( Picture 49 & 50 )
9.Route the harness alongside the Large Battery RED Cable and against the Battery Cable on the Trunk centerside
10.Cable tie the harness in place next to the Battery large RED Wire with 8 inch cable ties (Pictures 51, 52 & 53 )
11. As you route the Harness over the trunk make sure that the Harness is not tight against the trunk lip and is routed UNDER the Signal Cable below the trunk Lip use a 8 inch Cable ties to tie the Harness to the Signal Cable ( Picture 54 )
13.Route the harness along the inside of the Signal cable toward the rear fuse holder Box ( Picture 55 )
14.Route the end of the harness ( 1/4 inch ring terminal ) under the Battery to rear fuse box Red Power Cable and next to the stud holding the Battery to rear fuse box power cable to the rear fuse box.( Picture 56, & 57 )
15. Using a 10mm wrench remove the nut that holds the RED lead from the battery to the rear fuse box on the Rear Fuse Box ( Picture 58 )
16.Place the 1/4 inch terminal from the harness that you just placed next to the stud on the rear fuse box power stud and reinstall the nut and tighten ( Picture 58 )
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
17.Bend the Harness fuse Holder lead such that the open end of the harness fuse holder( where the fuse is inserted ) points toward the center of the trunk and the fuse holder is tight against the side of therear fuse box ( Picture 58 )
18.Cable tie the harness to the signal cable right next to the rear fuse box and space 4 cable ties between the rear fuse box and the plastic cable holder at the top trunk lip (Pictures 59)
We are now done routing the Harness from the Power relay to the Rear fuse box
It's now time to work on the other end Power from the Relay to the FORE Fuel Hat, Power to the Relay Relay enable and the Fuel Level Transmitters
Now that the Harness is routed and cable tied & taped in place now the fun starts (Ha Ha ) The Car at this point still runs but not for long ......
It' s time to upgrade the Fuel Hat
1.Lift off the black plastic cover that covers the OEM Fuel hat
2.Disconnect the electrical connector from the OEM harness to the White plastic OEM fuel Hat top
3.Pull the Rubber grommet out of the Black Plastic Fuel Hat Cover
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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire
THE FOLLOWG IS VERY IMPORTANT AND IF YOU DON'T FOLLOW THE LISTED STEPS THE RESULT COULD BE THAT THE FUEL HAT WON'T WORK OR YOU WILL GET IMPROPER FUEL LEVEL READINGS AND COMPUTER CODES
1.Remove the tape around the Wiring between the Black fuel hat cover and the Fuel hat connector and around the Rubber grommet and the tape covering the 5 wire cable all the way back to the Driver's side arm rest and 4 inches under the Driver's side arm rest
2. BE SURE YOU DO THIS write down on a piece of paper the wire color code for each of the 5 OEM Connector pins . DON'T LOOSE THIS INFO On the wire on pin #1 put one magic marker ring on this wire on Pin #3 put 3 magic marker rings on the wire. ( Picture70, 71,72,73 While theConnector Numbering and wirefunctions are Correct for all installs the Wire colorcode might not be so be sure you write down YOUR COLORS