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



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Page 1

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 cut thin 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 the 4 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 Loom or 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 Remove the 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 of the Seat Back between the seat half's . Pull the Seat Back on the Pass. side forward lifting the Seat Back bracket off the studs, Passenger seat and center Studs and then pull on the Passenger Seat till it clears the pin. Remove the Passenger seat and set it aside outside the car . Pull the Drivers side Seat Back off the its Bracket and 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 install Prerp 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 pulled out the plastic "Push Pins" and pull it toward the front seat exposing the rear back seat back mounting studs. 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 trunk center 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. Use the separate piece of sandpaper provided to remove any remaining paint in the 1 inch Dia. that the Wood sanding 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. Run the Harness along the back side of the Mounting brackets toward the Passengers wheel plastic cover and then alongside the battery cable over the 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 serrated Cassel nut and thread onto the stud making the nut hand tight. Holding the terminal in position tighten 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 )

4 Tape 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 the rear 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. ( Picture 70, 71,72, &73 While the Connector Numbering and wire functions are Correct for all installs the Wire color code might not be so be sure you write down YOUR COLORS

Page 13

FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire



This is it from this point on there is NO turning back The car won't run from this point on until you are DONE

1. Using a wire cutters cut all 5 wires 3 inches back from the OEM Fuel Hat connector.

2. Un twist the wires that were on pins Number 4 & #5 these are the largest of the 5 wires and are the OEM Fuel harness Power leads, pull these 2 wires out of the rubber grommet and untwist all the way back to the arm rest and 4 inches under the Arm rest then re twist them into a 2 conductor cable.

3. Pull the remaining 3 wires out of the rubber grommet and twist into a 3 conductor cable

4 Cut the rubber Grommet from 1/4 inch from one edge straight across the center of the grommet to 1/4 inch from the other edge Cut from the Fuel Hat side and set aside you will be reusing it shortly the Grommet has to be cut for the Power Connector & Fuel Level Connector to fit thru

Its solder time . Time to solder pins on the wires that you just cut off the OEM harness Connector

1. Locate the large Female 2 Pin connector and 2 Large Female Pins for this connector 1 Secondary connector rear lock same secondary lock as on the Harness 2 Pin connector and 2 Wire Seals ( Red/Orange in color ). These parts are in a plastic bag labeled " 2Pin OEM Cable -Relay Enable ( Picture 60 )



Page 14

FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire

2 Hold the 2 conductor wire in hand and pull out any slack and measure 3 inches from the Arm rest and then cut the wires at that point. Take one each of the Red/Orange wire seals and slide it onto each of the wires with the small end facing toward the end of the wire. Take a wire strippers and strip 3/16 of an inch of insulation off the end of each wire, Crimp on each of the wires a female and then solder each pin

3 . Insert the wire that was in the OEM connector Pin # 5 Look at your wiring notes into the 2 Pin Connector pin # A marked on the back lip of the connector with the pin lock facing toward the center of the Connector. This was the OEM Pump Ground wire and is now the Power Relay Coil Ground

4. Insert the wire that was in the OEM connector Pin #4 into the 2 pin connector Pin # B marked on the back lip of the connector with the pin lock facing toward the center of the Connector this was the OEM Fuel Pump Positive wire + 12 VDC and now will be the Relay Coil Power

5. Slide the Wire seals into the back of the connector push with a Small flat object so that the wire seals are flush with the back of the connector

6. Attach the Blue Secondary seal to the connector look at the Harness Connector to see how it attaches ( Picture 61 )

7. Slide 14 inches of 1/4 inch Split Wire loom over the 2 conductors butting up against the back of the connector and going under the arm rest cut off any excess as needed for a good fit



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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire

8. Mate up the 2, 2 pin connectors. Place the 2 pin connector assembly under the arm rest and using 2 pieces of 6" x 2'' Al tape the harness 2 Pin Branch Cable in place

You now have power to the Relay to Power up the Pumps Lots of progress One more connector to solder and then you are done soldering ( for now )

1. Locate 1 connector Which is a Small Female 3 Pin connector and 3 small Female Pins for this connector, 3 Wire Seals Green in color These parts are in a plastic bag labeled " 3Pin OEM Cable -Fuel Level Transmitters ( Picture 62 )

2 On each of the 3 wires the small 3 wires you twisted together untwist a little and slide a Green wire seal onto each wire with the small end facing the wire end. Strip 3/16 of an inch of insulation off each wire and crimp a female pin on each wire and then solder each pin

3 . Insert the wire that was in the OEM connector Pin # 1 Look at your wiring notes into the 3 Pin Connector pin # A marked on the back lip of the connector with the Pin Lock facing toward the bottom of the Conductor

4 . Insert the wire that was in the OEM connector Pin # 2 Look at your wiring notes into the 3 Pin Connector pin # B marked on the back lip of the connector with the Pin Lock facing toward the bottom of the Conductor

5 . Insert the wire that was in the OEM connector Pin # 3 Look at your wiring notes into the 3 Pin Connector pin # C marked on the back lip of the connector with the Pin Lock facing toward the bottom of the Conductor



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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire

6. Slide the Wire seals into the back of the connector push with a Small flat object so that the wire seals are flush with the back of the connector

7. Attach the Purple Secondary seal to the connector look at the FORE/Arrington Fuel Hat Connector to see how it attaches ( Picture 63 )

8. Slide 24 inches of 1/4 inch Split Wire loom over the 3 conductors butting up against the back of the connector and going under the arm rest cut off any excess as needed for a good fit

The soldering is done for now and next it is the final assembly we are getting close to being done

Final Fuel Hat Harness Connector Assembly ( It's about time )

1. Lay out the Harness connectors in the Area where they are going to be routed ( picture 64 )

2. Take the FORE/Arrington Wire Harness 4 Pin Large Connector and slide it thru the Slit in the Rubber Grommet with 3 inches of wire past the rubber Grommet ( Picture 65 )

3. Take the 3 Pin Small connector that you just soldered and slide it thru the slit in the Rubber grommet such that you have 4 inches of wire past the end of the rubber grommet. ( Picture 66 )



Page 17

FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire



The Harness wiring is now done ...It's time to Remove the OEM Fuel Hat

1. Remove the Fuel Hat Locking Ring that is holding the OEM Fuel Hat in place the locking ring needs to be rotated 1/2 inch Counter Clockwise to be removed. Use the 5 lb hammer and the 3/8 inch rod to apply force to the locking ring to remove it as It takes a lot of force to remove when removed set it aside

2. Have towels on hand and start up your fan before proceeding

3. Carefully lift the OEM Fuel hat up it might be stuck to the "O-ring so use a just little force if needed and let all the fuel in the OEM Fuel Basket drain back into the Gas Tank. Use the rags to wipe up any Gas that runs out of the tank

4. Disconnect the 3 hoses and the electrical connector from the Passenger side fuel level transmitter. VERY IMPORTANT RECORD THE WIRE COLOR CODE FOR THIS CONNECTOR RECRDING THE COLOR CODE FOR PIN #1 & PIN #2 and then cut these wires at the connector Pictures 72, 73,& 74

5. The Fuel supply hose has a BLUE push lock on it. Push the blue locking tab down and pull the hose off its connection . The 2 semi-transparent hoses one large & one small are removed by pushing up on the bottom of the hose . Drain out all the fuel in the basket before removing it from the tank set aside when drained.

6. The FORE/Arrington Fuel Hat comes with 2 external connectors one that mate's up with the FORE/Arrington Harness 4 Large Pin Fuel Pump Connector and the Second that mates up with the 3 Small Pin Fuel Level transmitter Connector that you solder up

Page 18

FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire



FORE /Arrington Fuel Hat internal Fuel level Transmitter Wiring

7. Disconnect the remaining electrical connector from the Bottom of the OEM Fuel Hat transmitter. VERY IMPORTANT RECORD THE WIRE COLOR CODE FOR THIS CONNECTOR RECORDING THE COLOR CODE FOR PIN #3 PIN #4 and then cut these wires at the connector Pictures 72, 73,& 74

8. Remove the Driver's side Fuel Level Transmitter from the OEM Fuel Hat and install it on the FORE Fuel Hat it pivots and slides on from the side and is held in place by a bracket and 2 screws

See Pictures 70, 71, 72, 73, & 74 for information on wiring the FORE/Arrington Fuel Hat Internal Fuel Level Transmitters . For Passenger Side Level Transmitter and the Driver's Side Level Transmitter and use this info. when wiring up the Fuel Level Transmitters

9 FORE Precision Products supplies along with the FORE Fuel Hat 4 Quick Connect Mini Male Connectors and 4 pieces of Shrink Tube to cover the 2 connections for the Driver's side Fuel Level transmitter and the 2 Connections for the Passenger's side Fuel Level Transmitter These connectors need to be soldered

`10. The following is the FORE Fuel Hat Internal Wire Color Code

Small Yellow Wire #20 Wire is for the Passenger's Side Fuel Level Transmitter Return Wire Connection and needs to be connected to the wire that was on Pin #1 of the OEM bottom side Connector on the OEM Fuel Hat Solder one Mini Connector to this wire



Page 19

FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire

11. Small Black Wire (#20 Wire ) with a Small Black Wire Jumper attached these 2 Wire Connectors One of the Small Black wires is for the Driver's side Fuel Level Transmitter Supply. The other small Black Wire is for the Passenger's side Fuel Level Transmitter Supply . Connect one of the Small Black wires to the wire that was connected to Pin #2 on the OEM Bottom side Connector on the OEM Fuel Hat and the other that was Connected to Pin #3 of the OEM bottom side Connector on the OEM Fuel Hat Solder one each mini Connector to each of these wires

12, Small Blue Wire ( #20 Wire ) is for the Driver's Side Fuel Level Transmitter Return Wire Connection and needs to be connected to the wire that was on Pin # 4 of the OEM bottom side Connector on the OEM Fuel Hat Pictures solder a Mini Connector to this wire



Now with all the FORE Fuel Hat wiring completed we are ready for the final Assembly

Do Step ! & 2 Together

1. Lower the FORE Fuel Hat Part way into the Fuel Tank and connect up the Driver's Side Fuel Level Wires & the Passenger's Side wires MAKE SURE YOU FOLLOW THE COLOR CODE AND WIRING INFORMATION ON PAGE 18 AND PICTURES 72,73,74

2. Use the Shrink Tube supplied by FORE to cover the connections and Shrink in place

3. When done connect up the Fuel Lines there is one with a blue locking collar on it. Depress the Blue lock and slide the line onto the FORE Fuel Hat Fuel outlet connection This is the easy part )



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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire

4. Slide a hose clamp on to each of the 2 remaining fuel lines ( Semi- transparent lines ) and slide them over their connectors ( there is a big size difference ) and tighten the hose clamps take your time

5. Set the FORE Hat in place and install the locking ring again it is going to take a lot of force to lock in place

6. Insert the Rubber Grommet with the 2 cables and 2 connectors into the Black Plastic Fuel Hat cover and push in place ( Picture 66 )

7. Move the Black Plastic cover with the rubber grommet in place over the FORE Fuel Hat and connect the 2 Connectors the 4 Pin Power connector and the 3 pin Fuel level connector ( Pictures 67 )

8. Put the Black Plastic Fuel Hat cover back in place ( Picture 68 )

9. Tape the Harness in Place using the last of the Al Tape ( Picture )



YOU ARE NOW DONE WITH THE FORE FUEL HAT REPLACEMENT AND THE WIRING UP GRADE NOW ON FINSHING UP & TO TEST

Time to finish up and Crank up the Car ( with lots more fuel Pressure )

1. RECONNECT THE BATTERY INSURE THE BATTERY IS UP TO STARTING THE CAR

2. INSERT the 25 AMP FUSE INTO THE HARNESS FUSE HOLDER CHECK TO SEE THAT THE FUSE DOES NOT BLOW UPON INSERTING

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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire

3. TURN ON THE ING. THE FUEL LEVEL SHOULD READ THE SAME AS BEFORE YOU STARTED ( UNLESS YOU LOST A LOT OF GAS WHEN REMOVING THE OEM FUEL HAT )

4. IF THE ABOVE 3 STEPS ARE GOOD THEN PROCED TO STEP 5

5. START THE CAR ( BECAUSE THERE IS NO FUEL IN THE LINE AND THE PRESSURE IS ZERO IT CAN TAKE ANYWHERE FROM 1 TO 3 STARTING ATTEMPS

6. Give your setup a good looking over make sure everything looks OK and the Harness is not heating up and there are no Gas leaks

If All looks good and the car runs you did a great job take the car out for a short spin to verify that all is good take your cell phone along

NOTE: Because the FORE/Arrington Fuel Hat with the High Current Wire Harness will be supplying Fuel at a Higher Pressure at the Fuel Rails ( unless you have a Fuel Pressure Regulator ) you might need a slight adjustment to your Tune If you have a AFR gauge note its readings durning your test

Seeing that all is OK Now let's put the car back together

1. Install everything you removed from the Car in reverse order

2. Put the thin foam from the back seat area back in place

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FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire

3. Put the Back seat Back in place with the 5 nuts, you need to put the back seat Back behind the driver's side into the Car first then put the Drivers back seat mounting bracket on to the mounting studs and put the 2 mounting nuts on with ONLY 1 TURN. Now put the pass side Back seat back into the Car, slide the pass seat back onto the driver's side seat back pin then put the driver's side back seat back center bracket on its mounting studs and put the passenger side seat mounting bracket on its mounting stud put on the remaining 3 nuts and tighten all 5 nuts

4. Put the back seat bottom back in place Push it down and in, in the back and push the front toward the back and down

5. Put the Rear fuse box cover back in place

6. Put the spare tire back in place and secure with its plastic hold down

7. Put the Trunk bottom cover back in place

8. YOU ARE DONE ENJOY



Go fill up the gas tank as you should never operate the car with less than 1/4 tank of Gas

CONGRADS you have done a heck of a job You will now have lots of Fuel to burn

Page 23

FORE Fuel Hat Harness Install into a Dodge Challenger with a Spare Tire

Any questions on the Harness, the install, comments or suggestions PLEASE E-MAIL or Call

RDW LLC


Richard

richard.wamser@sbcglobal,net

1-414-422-0665

Revision B 10-6--2010 RDW LLC



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