It's 10pm - where's your lift pump?

gmctd · **Posted:** Sat Mar 29, 2008 2:52 pm

No prob - your clear pics contribute much needed data, so your input is appreciated

From PM -

Unclip and remove that retainer from the back of the connector shell
- pull that red plastic plug out of the front of the shell with a pair of needle nose pliers - just tug hard and it will pop out
- pull the large rubber seal out of the shell and backward along the wires about 3-4", so you can work with the wires - it's difficult because it is a waterproof seal, so be careful not to tear the rubber
- push the wire in question forward into the connector - from the front, you can see the pin with a small plastic tab down against it
- take a small sharp tool, lift that tab away from the pin, pull the wire out backwards
- push it into the correct new location till the tab snaps into the rectangular hole in the pin
- continue accordianly

Ripster · **Posted:** Sat Mar 29, 2008 5:59 pm

The plug is done, here are some pics.

Pull this red plug using the two bumps on it with pliers, it will slide and the pop out, no harm.

These are the clips before moving them, you can see the tab you pry back so they
slip right out, used a dental pic from the hardware store. 2nd clip down on the left
shows the tab very well that you will lift to allow the wires to slide out easy.

#1 is upper right, #10 lower left with the white plug in it.
#2, 4, 5 were not moved #6 7 were removed and taped to side of harness.
#1 and #3 are now in #8 and #9 per gmctd's instructions above.

http://picasaweb.google.com/crdturbo/CRD

gmctd · **Posted:** Sat Mar 29, 2008 7:51 pm

Good job, then - and, it is a good idea not to cut any of the extra wires in the connector - as noted, tape them back in case you want to add something, later

BTW - what were you using for a camera?

gmctd · **Posted:** Sat Mar 29, 2008 9:42 pm

Looks like this will be the finalized wiring connections for upgrading '05 and '06 CRD KJ's with the '05-'07 Dodge Cummins lift pump module

Required is -

MODULE, FUEL PUMP (fuel transfer pump) 2005^ Dodge 3500 Cummins
5143160AA $156.21

WIRE HARNESS, FUEL TANK 2005 LIBERTY 3.7L
56050284AB $35.85

WIRE HARNESS, FUEL TANK 2006 LIBERTY 3.7L
56047848AB $51.78

(Airtex E7187M transfer (lift) pump - ~$170)

Dropping the fuel tank - not too difficult, even easier with a helper - removing the Jeep fuel module - installing the DC lift pump module - rewiring the CRD rear harness for lift pump power, using the V6 harness

1@ '05-'06-'07 Dodge 2500\3500 Cummins fuel tank module with 9psi 5amp continuous duty fuel transfer (lift) pump

1 @ KJ I4\V6 fuel tank harness to match your year model - the connectors are different, as '05 has 10pin RW-ABS, '06-'07 has 14pin 4W-ABS

Or, any year - just transfer the Black ground wire and Green\Orange stripe or Blue\Red stripe power wire to your harness - the connector terminals are easily removed and transferred.
Or, add the 4wire fuel tank connector and wiring from any year to either year.
_____________________________________________________________________________________________________

Add-wiring pics in this thread:
http://www.lostjeeps.com/forum/phpBB3/vie ... 109#315109

OEM '05 CRD termination, add lift pump wiring, only
1......n\c
2......n\c.........add lift pump wire here
3......n\c
4......Grn\Blu...RWSS
5......Grn.........RWSS
6......n\c
7......n\c
8......Brn..........Fuel guage....(DkBlu - V6 fuel tank wiring)
9......Brn\Grn....Fuel guage....(DkBlu\Yel - V6 fuel tank wiring)
10.....n\c
Lift pump ground is separate Black wire grounded to floorpan, bypassing connector

For '06, add lift pump Black ground wire and add Grn\Or power wire to pin 2 - see '06 14pin connector, listed below
______________________________________________________________________________________________________
C307 10pin connector wiring for '05 KJ's-

'05 V6____________________ Rewired for '05 CRD, or V6 fuel harness
1 -- Fuel Guage Sender gnd ___ 1 - n\c
2 -- Lift Pump ______________ 2 - Lg Grn\2Rd - Lift Pump
3 -- Fuel Guage Sender sig ____ 3 - n\c
4 -- RWSS _________________ 4 - Grn\Blu - RWSS
5 -- RWSS _________________ 5 - Grn - RWSS
6 -- Vacuum Leak Detector_____ 6 - n\c, don't care
7 -- Vacuum Leak Detector_____ 7 - n\c, don't care
8 -- n\c ____________________ 8 - Brn - (DkBlu - V6) - Fuel Guage Sender gnd
9 -- n\c ____________________ 9 - Brn\Grn - (DkBlu\Yel - V6) - Fuel Guage Sender signal
10 - n\c ___________________ 10 - n\c
Lift pump ground is separate Black wire attached to the floorpan, bypassing the 10pin connector

'05 pics in this thread:
http://www.lostjeeps.com/forum/phpBB3/vie ... 907#317907
______________________________________________________________________________________________________
C307 14pin connector for '06 KJ's -

'06 V6 ________________________'06 CRD (oem wiring installed in cabin connector)
1 -- n\c ______________________. 1 -- n\c..........(Blu\Grn)
2 -- lift pump _________________. 2 -- LgGrn\Orn .... Lift pump
3 -- RR ABS __________________. 3 -- n\c..........(Blu\Yel)
4 -- RR ABS __________________. 4 -- Grn\Blu ........ RWSS
5 -- ESP ______________________ 5 -- Grn\Gry ....... RWSS
6 -- Vacuum Leak Detector _______ 6 -- n\c ....... (Vio\Gry)
7 -- Vacuum Leak Detector _______ 7 -- n\c ....... (Vio\Wh)
8 -- fuel guage _________________ 8 -- Brn\Grn ........ Fuel Sender
9 -- fuel guage _________________ 9 -- Brn ............... Fuel Sender
10 - LR ABS ___________________ 10 -- Grn\Yel ......... RWSS
11 - LR ABS ___________________ 11 -- Wh\Grn ......... RWSS
12 - n\c ______________________. 12 -- n\c
13 - n\c ______________________. 13 -- n\c
14 - n\c ______________________. 14 -- n\c
Lift pump ground is separate Black wire attached to the floorpan, bypassing the 14pin connector

'06 pics in link in this thread:
http://www.lostjeeps.com/forum/phpBB3/vie ... 189#301189

_____________________________________________________________________________________________________

The large bulkhead pass-thru in the floorpan is easily removed from beneath (after unbolting and moving the seat and carpet) by depressing four tabs on the in-cab circumference.

ECM-controlled power wiring is furnished to the connector under the left rear seat, oem-rated 10amp continuous duty - just plug'n'pump with only minor connector pin reconfiguration
Reference - http://www.lostjeeps.com/forum/phpBB3/vie ... hp?t=23099

It's not over till it's over, so many thanks and much appreciation to all who contributed, and continue to contribute, and will contribute to the welfare and well-being of our little orphaned-by-Jeep mule

jd

Scott Langohr · **Posted:** Mon Mar 31, 2008 11:58 am

Started feeling the fist sign of the "55 MPH shudder" this week end. All winter long, it has been taking progressivly more cranks to start. I got a little air out of the bleeder but not much. I ordered the parts this morning per previous instructions (parts and shipping totaled 199.00). I hope the '05 harness is available to ship. It's been 4 hrs and I have not been notified of a problem yet. These last posts and pictures have really helped my understanding of the wiring process. Is it possible to suck out any of the fuel from the tank through the filler? I do not have any help available and getting the tank down and back up again concerns me a little. I'll be glad to put this fix to work for me then I can move on to the next one on the list.

Since this fix has proven to stop the shudder by the many owners that have installed various lift pump configurations, can we assume the detuning recall (F37 I believe) to save the torque converter was not necessary? Am I mistaken in thinking that the shudder was attributed to a TC failure or is the TC problem a totally different issue. I would do the Inmotion re-flash sooner if I can feel it will not do damage to the TC. Just trying to set the priorities in order.

honey_don't · **Posted:** Mon Mar 31, 2008 12:13 pm

Scott Langohr wrote:

Is it possible to suck out any of the fuel from the tank through the filler?

An easy way to siphon:
--Get a fuel container and take off the top
--feed one end of hose into tank, other end into container a few inches at least
--stick nozzle of shop-vac into container mouth alongside fuel hose
--wrap hand around container mouth, vac nozzle and hose to create seal
--run shop-vac, resultant vaccum will suck fuel from tank into container
--adjust rate of transfer by adjusting the seal created by your hand.

If you use a floor jack to lower the mostly empty tank it's no prob for one person. I had my wife stabilizing one side of the tank but that was really unnecessary. I had stacks of 2x4 scraps on each side of the jack, lowered the tank onto those, pulled the jack, and then pulled the 2x4s alternately one at a time till it was on the ground and could clear the bumper.

stp2136 · **Joined:** Sat Sep 29, 2007 8:30 am **Posts:** 35

Don't know if all units were built the same but when I dropped the tank to put in the lift pump I noticed that there is a screen in the filler hole of the tank. Might be a little difficult to get a hose in to siphon.

I used the '06 V6 harness but of course I had to move wires in the cabin connector--fuel gage and both speed sensors, as noted in previous posts. Seems to work fine so far.

gmctd · **Posted:** Tue Apr 01, 2008 2:08 am

Good input, stp - and, just looking at your sig, it would appear that you've been doing any number of things on the quietus - feel free to post your results after your upgrades - all input is welcome, and necessary for the database - f'rinstance: did you lengthen the '06 harness in any way to make it fit?

stp2136 · **Joined:** Sat Sep 29, 2007 8:30 am **Posts:** 35

Didn't have to lengthen the harness. The '06 V6 harness fits perfectly in the '06 CRD. Of course there are extra wires and connector for the vacuum pump in the gasser and the wires for the fuel gage and for the speed sensors need to be moved but all the changes are done in the cabin connector. I just laid out both harnesses side by side to compare. One of the speed sensors was in the correct position but reversed polarity. It probably doesn't matter but I corrected that since it is easy enough to do.

I used the hand pump to purge air out before starting. With the driver door open you can easily hear the new lift pump run for the 25 seconds when you turn the key on. It started and ran fine. Thanks to all who have contributed info--it made the job easy.

One remaining issue: I still notice driveline vibration with heavy throttle after lockup between 40 - 55 MPH. It comes and goes as the speed changes. I see at least two factory kluges to try and address the problem: A dampener on the front end of the rear driveshaft and an extra weight hanging on the rear diff. Maybe that is an issue for another thread.

fastRob · **Posted:** Tue Apr 01, 2008 9:00 am

Is it time to check out and remove any residue in the tank?
To modify the filler neck for easy filling?
I'm anxious to order the pump and wires but will do the SEGR first. One thing at a time.
R

gmctd · **Posted:** Tue Apr 01, 2008 12:06 pm

Ok, good news on the '06 harness length, stp - the '07 V6 harness I used was correct length for the '05 KJ, also.

Those weights on the driveline are to compensate for 4cyl engine firing pulses - only two violent thrusts per crankshaft revolution, where a 6 or 8 has enuff to smooth out the effect - the Diesel 4cyl generates even more violence, as the crank is also fighting against the high cylinder pressure on the compression stroke - your shudder may be related to all the oem-installed 545 problems, detuning and depressurizing to compensate for that plastic stator - I'd suggest easing up on the acceleration till we get something accomplished in the ECM and TCM, or you could try adding that 2kohm offsetting resistor to the pressure sensor, there on the exhaust-pipe side rear of the 545 case, to increase line pressure, see if that helps - if you also use a potentiometer, you could vary the amount of offset, thus variable pressure from stock to full increase - or, a simple switch, to turn it on and off, for R&D

Rob, it would indeed seem prudent to do a little investigative inspection during a dropping the fuel tank procedure - any detritus may be hard to see, as the tank is black anti-static thermoplastic - those black plastic fuel lines are also anti-static compound

dgeist · **Posted:** Tue Apr 01, 2008 12:48 pm

gmctd wrote:

Ok, good news on the '06 harness length, stp - the '07 V6 harness I used was correct length for the '05 KJ, also.

Those weights on the driveline are to compensate for 4cyl engine firing pulses - only two violent thrusts per crankshaft revolution, where a 6 or 8 has enuff to smooth out the effect - the Diesel 4cyl generates even more violence, as the crank is also fighting against the high cylinder pressure on the compression stroke -

Off, topic, but is that why it feels like I'm wobbling a bit when I'm in stop-go traffic an idling along at 15-20 mph? I can almost get the wobble to resonate and bounce the suspension around if I hit the right speed. Over 30 mph and it completely smooths out, hence I wasn't suspecting the tires. Also, it happened with the stock tires and the current ones, so that baffled me even more...

gmctd · **Posted:** Tue Apr 01, 2008 1:12 pm

Difficult to say, without experiencing it - the engine is on liquid-filled rubber supports, intended to dampen\isolate those firing pulses, as are the dual balance shafts - how are your lower ball joints?

#1son's Cherokee did a sorta slow speed wobble with wide rims and over-sized tires, shoulda had a better front-end alignment for that cure, maybe less camber, more toe-in, or a little more caster, or all the above

Scott Langohr · **Posted:** Tue Apr 01, 2008 3:06 pm

Moparpartsamerica emailed me and said the parts will be delayed due to the wire harness is special order. I have been given a revised date of April 15th. That is not so bad and I can wait in this case. (Ordered the '05 gasser harness 56050284AB)

fastRob · **Posted:** Tue Apr 01, 2008 5:44 pm

Scott Langohr wrote:

Moparpartsamerica emailed me and said the parts will be delayed due to the wire harness is special order. I have been given a revised date of April 15th. That is not so bad and I can wait in this case. (Ordered the '05 gasser harness 56050284AB)

While I was price checking they sold out on wiring harnesses, told me good luck finding one for the '06.
Will try junk yards tomorrow. The dealer suggested a couple.
The pump is "in the mail."

R

clday25 · **Posted:** Tue Apr 01, 2008 6:41 pm

Ok, tonight I’ll take an inventory of what's left of the 05 wire harness I took apart for my lift pump mod. I'm willing to mail out what I’ve got left over.

Looks like i only have enough conncectors left for two harness-mods and 05infernoCRDL called dibs.... sorry

IMO, you really only need to add the power and ground wire to your stock harness. It comes down to having the two wire ends for the lift pump and the one wire end for the body connector. You can come up with your own ground connector. I should have enough ends for two harness-mods, but maybe more. Also, my 05 stock harness was approx. 66" long.

With all the info on this subject is was pretty easy to do, even for me :wink:

Later,
Chris

05infernoCRDL · **Posted:** Tue Apr 01, 2008 6:47 pm

clday25 wrote:

Ok, tonight I’ll take an inventory of what's left of the 05 wire harness I took apart for my lift pump mod. I'm willing to mail out what I’ve got left over.

IMO, you really only need to add the power and ground wire to your stock harness. It comes down to having the two wire ends for the lift pump and the one wire end for the body connector. You can come up with your own ground connector. I should have enough ends for two harness-mods, but maybe more. Also, my 05 stock harness was approx. 66" long.

With all the info on this subject is was pretty easy to do, even for me :wink:

I'll edit this post when i figure out what I’ve got.

Later,
Chris

dibs on two if you got em

fastRob · **Posted:** Thu Apr 03, 2008 12:05 pm

So all I need is 1, a wire to plug into the 14 pin connector (10 pin on the 05) for juice to the lift pump with a 2, connector at the other end to the lift pump and 3, a ground wire with end on it.
or
2 wires, 1 ground end and one connector to the lift pump?

for $60. backordered or a junkyard visit?

R

05infernoCRDL · **Posted:** Thu Apr 03, 2008 12:52 pm

fastRob wrote:

So all I need is 1, a wire to plug into the 14 pin connector (10 pin on the 05) for juice to the lift pump with a 2, connector at the other end to the lift pump and 3, a ground wire with end on it.
or
2 wires, 1 ground end and one connector to the lift pump?

for $60. backordered or a junkyard visit?

R

I'll tell you the wire ends you need..
1 end for in the 14 pin connestion
1 end that has a ground terminal for the 14 pin side
2 ends that go into the plug at the fuel tank

for a rough view of the wires

14 pin connector side fuel tank side
--l------------------------------------------------------------------------------------------= power wire
Ol-------------------------------------------------------------------------------------------= ground wire

*edit*
a junk yard will do if you can find one... i foud roubles cause they are
so new... but i have small junkyards around me right now.

gmctd · **Posted:** Thu Apr 03, 2008 1:37 pm

'07 is same - fairly certain any KJ 4cyl\V6 should be same back to '02 - all you need is the Grn\Or power wire and the Blk ground wire - the power wire has a female connector terminal pin on one end, male on the other - the ground wire has a female connector terminal pin on one end, a ring-lug terminal on the other

Fuel module connector (female) gets Black ground on pin1, Grn\Or power on pin4 - rear cabin connector (male) gets Grn\Or power on pin2 - Black ground wire is screwed to the dedicated grounding tab on the floorpan

The fuel module connector uses the same female terminating pins as the rear cabin connector - MrMoparts should have the matching male and female pins - rear cabin connector should be C307

It's 10pm - where's your lift pump?

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