I'm installing a new fuel pump wiring harness in my D1 (AEL). What's the trick to getting the old one out and new one in? The problem I'm running into is that the plugs are too big to fit through the gap between the cargo area floor and the chassis cross member.
I have removed the fuel lines from the pump and moved them to the side to make more space. I zip-tied the chassis end plug of the new wiring harness to the fuel pump end of the existing harness thinking I could pull the old one out while pulling the new one into position. Lying under the truck, pulling towards the front of the truck, I moved the wiring part of the harness far enough to where the plugs reach the gap but can't fit through.
If I reverse the removal process and pull from the fuel pump end, I am going to encounter the same thing because the chassis end plug of the old wiring harness will be too big to fit through the gap, although I could cut off the old chassis end plug and try to thread the smaller pump end plugs through the gap.
There is a hard pipe running along the top of the chassis cross member that reduces the clearance for the plugs to pass through. Trying to move that doesn't seem like a good idea, although it does clip into place along the top of the cross member. Perhaps I could remove the pipe from the clip and get enough play to widen the gap for the plug. For those of you have done this job before, what's the secret to getting the plugs through that gap?
Edit: I suppose I could cut one plug end off and splice it once the new harness is in place, but I feel like there must be a simpler solution.
I have removed the fuel lines from the pump and moved them to the side to make more space. I zip-tied the chassis end plug of the new wiring harness to the fuel pump end of the existing harness thinking I could pull the old one out while pulling the new one into position. Lying under the truck, pulling towards the front of the truck, I moved the wiring part of the harness far enough to where the plugs reach the gap but can't fit through.
If I reverse the removal process and pull from the fuel pump end, I am going to encounter the same thing because the chassis end plug of the old wiring harness will be too big to fit through the gap, although I could cut off the old chassis end plug and try to thread the smaller pump end plugs through the gap.
There is a hard pipe running along the top of the chassis cross member that reduces the clearance for the plugs to pass through. Trying to move that doesn't seem like a good idea, although it does clip into place along the top of the cross member. Perhaps I could remove the pipe from the clip and get enough play to widen the gap for the plug. For those of you have done this job before, what's the secret to getting the plugs through that gap?
Edit: I suppose I could cut one plug end off and splice it once the new harness is in place, but I feel like there must be a simpler solution.
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