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    STAR Case: Case Number: S1308000399 Release Date: 05/29/2013 Symptom/Vehicle Issue

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    inversiones tecnologicas Invertecaca
    This document provides a repair procedure for a vehicle with an intermittent crank no start issue caused by the fuel pump relay. The procedure involves installing an external fuel pump relay and control circuit using a relay kit, inline fuse, wire terminals and connectors. Key steps include splicing into existing fuel pump and ignition circuits to provide power to the new relay and mounting the relay under the hood.

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    Download as PDF, TXT or read online from Scribd

    STAR Case: Case Number: S1308000399 Release Date: 05/29/2013 Symptom/Vehicle Issue

    Uploaded by

    inversiones tecnologicas Invertecaca
    93 views5 pages
    This document provides a repair procedure for a vehicle with an intermittent crank no start issue caused by the fuel pump relay. The procedure involves installing an external fuel pump relay and control circuit using a relay kit, inline fuse, wire terminals and connectors. Key steps include splicing into existing fuel pump and ignition circuits to provide power to the new relay and mounting the relay under the hood.

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    FallaDodgeRam

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    This document provides a repair procedure for a vehicle with an intermittent crank no start issue caused by the fuel pump relay. The procedure involves installing an external fuel pump relay and control circuit using a relay kit, inline fuse, wire terminals and connectors. Key steps include splicing into existing fuel pump and ignition circuits to provide power to the new relay and mounting the relay under the hood.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    93 views5 pages

    STAR Case: Case Number: S1308000399 Release Date: 05/29/2013 Symptom/Vehicle Issue

    Uploaded by

    inversiones tecnologicas Invertecaca
    This document provides a repair procedure for a vehicle with an intermittent crank no start issue caused by the fuel pump relay. The procedure involves installing an external fuel pump relay and control circuit using a relay kit, inline fuse, wire terminals and connectors. Key steps include splicing into existing fuel pump and ignition circuits to provide power to the new relay and mounting the relay under the hood.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 5

    STAR Case

    Case Number: S1308000399

    Release Date: 05/29/2013

    Symptom/Vehicle Issue:
    Intermittent Crank No Start

    Diagnosis:
    Vehicle does not start, fuel pump operates intermittently at times. Verify fuel pump relay output fuse is
    good Fuse M25 20 A and, circuit N1 DB/OR pin 10, C5 TIPM brown connector has no 12v power
    ouput.

    Parts Required:
    Relay kit 68142156aa
    Inline fuse 68217670aa
    20A fuse 000ATC20

    Additional parts needed


    Zip ties
    ¼ inch eyelet
    Corrugated Wire loom protector (24 inches)

    This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Center
    Online does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
    to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the appropriate
    course of action.

    Chrysler Group LLC Contact the STAR Center for assistance if no solution is found Version 5/23/13
    STAR Case

    Repair Procedure:
    Procedure to install an external fuel pump relay control circuit.

    1. Disconnect the battery prior to performing repairs.


    2. Attach blue wire terminals into the connector from relay kit (wire ends feed through top of
    connector/insulator, relay coil locations (85) and (86) coil control circuits.
    3. Install the green wire terminal to the relay connector location, switched side terminal location
    (87). Slide the corugated harness covering over the relay circuit wiring as shown.
    4. Connect the eyelet terminal to one end on the red inline fused circuit. Install the green wire into
    relay connector location (30) B+ feed. Work through insulator and corugated harness covering.
    Secure green wire to red by crimp splice to achieve overall length as seen below.
    5. Review the assembled harness and wiring to ensure completed as illustrated below.

    This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Center
    Online does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
    to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the appropriate
    course of action.

    Chrysler Group LLC Contact the STAR Center for assistance if no solution is found Version 5/23/13
    STAR Case

    Connecting relay and harness to vehicle

    1. Mount the relay at upper radiator core support (right side); attachment pilot hole in front of
    hood bumper.

    Hole attachment in
    upper support.

    Hood
    bumper
    adjust

    2. Unclip and roll TIPM to access the C1, 50 way black TIPM connector.

    This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Center
    Online does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
    to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the appropriate
    course of action.

    Chrysler Group LLC Contact the STAR Center for assistance if no solution is found Version 5/23/13
    STAR Case

    3. Cut circuit K31 engine fuel pump control, cavity 40 brown wire about 1 inch from the
    connector.Use heat shrink tube on the short wire on the connector side to seal. This will not
    be used in this repair. Solder the other end of the wire harness side K31 Brown wire to blue
    wire from relay terminal (85) of the relay harness. (use shrink tube to to seal all spliced areas).

    4. Install black connector on TIPM once complete.

    5. Remove the C5 TIPM brown connector and locate circuit N1 DB/OR Fuel pump circuit feed,
    cavity 10. Cut the wire about 1 inch from the connector. Use heat shrink tube on the short wire
    on the connector side to seal. This will not be used in this repair. Solder the other end of the
    wire harness side N1 DB/OR wire to the green wire from the relay terminal (87) of the relay
    harness. (use shrink tube to to seal all spliced areas).

    This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Center
    Online does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
    to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the appropriate
    course of action.

    Chrysler Group LLC Contact the STAR Center for assistance if no solution is found Version 5/23/13
    STAR Case

    6. Locate circuit F941 PWR IGN RUN/START PK/LG cavity 38 of the C5 Brown TIPM connector
    DO NOT cut this wire. Remove the wire from the connector to splice. About 2 inches from the
    connector trim insulation back to expose the bare wire. Solder this circuit to the blue wire from
    terminal (86) of the relay harness. Slip heat shrink tube over the terminal of F941 and seal the
    solder point. Install the wire back into the connector.

    7. Install the brown connector back onto the TIPM and secure the TIPM as needed.

    8. Attach Fused relay eylet, red wire from the relay harness terminal location (30) to the B+
    terminal post of the TIPM.

    9. Test the operation to complete.

    LOP: 08 90 65 37 1.0 hr

    This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Center
    Online does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
    to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the appropriate
    course of action.

    Chrysler Group LLC Contact the STAR Center for assistance if no solution is found Version 5/23/13

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