FUEL PUMP WIRING IS BAD WITHIN A FEW INCHES OF ...
2005 Dodge Caravan
December, 31, 2012 AT 12:12 AM
Fuel pump wiring is bad within a few inches of where wires go inside of body cavity. There isn't enough length to install a splice, and I don't have any idea how to access this internal wiring so that I could splice it. I was thinking about bypassing the wiring and running new wiring along the underbody from the in-line connector near the pump all the way to the IPM. I believe that there is non-slitted flexible conduit that would protect the wiring. However, I'm not sure if this is acceptable practice. I certainly don't want to do anything stupid and/or unsafe. I sure could use some expert help.
Wherever wire goes through body sheet metal it will go through a rubber grommet. You can tug on the wires to pull the grommet out, or you can pry it out with a screwdriver. Use a side cutter to cut half way through the grommet from the outer edge to the middle so the wires can be removed and new ones slid in. Splices outside the vehicle should always be soldered and sealed with heat-shrink tubing but I do that inside too. Never use electrical tape because it will unravel into a gooey mess on a hot day. Push the wires into the grommet so the splices are inside the vehicle, then pop the grommet back in. Use some black RTV gasket sealer from the Chrysler dealer to seal the gap where you cut the grommet and where the wires go through to insure no water gets in.