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This article walks through the steps on how to build your own Dual FPDM
Harness for your 2003/2004 Cobra or really any Mustang with a Returnless
fuel system that wants the capacity to run dual Ford GT pumps. Before I
get started I wanted to give credit where credit is due. This is the site
I based my build off of http://www.innovativesitedesign.com/03cobratech/gt40pumpupgrade.html
and has some great FAQ info about why this modification should be done
when running dual GT pumps. As well as 04sleeper for passing it on to me
and answering questions. The article here is just concentrating on the
harness assembly and to clarify a few things that weren't 100%
clear.
For the harness plug ends you really have two options. First is to hit the
local scrap yard and look for any 99+ Mustangs (V6, GT, Cobra) for FPDM
plug ends. They are quite easy to find and you get to work with the proper
wire colors for this build. If you can't find them or don't have the time
you can buy them from Ford for $25-30 each, Ford Part # 3U2Z-14S411-SAA. I
went with 40 amp relays for this harness but you could get away with
something a little less. Something else to think about is some type of
plug end for the wires going to the fuel pumps and the 8 gauge wire going
to the fuse box. Napa sells a connector that screws together from both
ends and they make it for 8 and 12 gauge wire. This allows you to
disconnect the harness at the fuel pump so you can drop the tank instead
of cutting and soldering the wires back together or so you can disconnect
the main power wire while doing work on the system.
FPDM Plugs
- The Grey/Pink
stripe wire from the FPDM plug and solder 10 feet of Red 12ga wire to
it as close to the plug end as you can and cover in heat shrink.
Repeat on second FPDM plug. If using the Ford plug with all black
wires refer to Figure 1 on the right for the corresponding wire
colors. These are your Positive + wires for your fuel pumps.
- The Red/Black
stripe wire from the FPDM plug and solder 10 feet of Black 12ga wire
to it as close to the plug end as you can and cover in heat shrink.
Repeat on second FPDM plug. These are your Ground - wires for your
fuel pumps.
- The White/Red
stripe wire from both FPDM plugs will be combined and soldered to the
amp bypass. Tape or zip tie these wires together till we are ready to
cover the bypass plug.
- Only one of the Light Blue/Orange
stripe wires is needed so on one plug end tape it off and on
the other you can either cut it short and cap it off or if you are
experienced with taking apart the plug ends you can remove that pin
all together. The remaining LB/O wire will go to the bypass plug.
- The Black wire from each FPDM plug should
be combined with the ground wires from the two relays, soldered
together and grounded in one location.
- The Pink/Black stripe
or Dark Green/Yellow
stripe wire from the FPDM plug will go to the 12V "Output"
from one relay. Crimp on or solder a female terminal connector. Repeat
on second FPDM plug and connect to the other relay.
Amp Bypass
- Plug in the amp bypass to one of the FPDM plug
ends. There are three wires you will need on the amp bypass the rest
can be cut and capped or the pins removed. One of the wires that you
will need does not have a corresponding wire in the pin location so
the plug has to be disassembled and a wire moved into that location.
Mark wires you need (see Figure 2).
- There is a locking clip that can be pushed out
from the back side of the amp bypass use the pick or other narrow tool
to push this out (see Figure 3).
- From the front side of the plug use the same
tool to release the individual clip holding in each pin and pull the
wire out from the back of the plug. Be careful as it is easy to break
the clip from pulling on the wire too hard. I removed all wires except
for the two that were needed then took of wires I removed and push it
into the back of the plug for the third wire that is needed.
- Take the corresponding wire from the back of the
amp bypass for the Light Blue/Orange
stripe wire and solder it to the one Light
Blue/Orange stripe wire from the
FPDM harness cover in heat shrink.
- Take the corresponding wire from the back of the
amp bypass for the White/Red
stripe wire and solder it to the two White/Red
stripe wires from the FPDM harnesses and cover in heat shrink.
- Take the corresponding wire from the back of the
amp bypass for the Pink/Black stripe
or Dark Green/Yellow
stripe wire and solder on two short lengths of 16 gauge wire and cover
in heat shrink. Crimp or solder on two female terminal connectors.
These two wires will go to the switch side of each relay.
Relays
- Run approximately an 8-10" length of 16ga
wire from the relay Ground (length varies depending on where you will
mount your relays and where you ground the harness) to the Ground
wires from the FPDM harness plugs. Repeat on other relay then combine
all four and solder. Crimp on a ring terminal so it can be grounded to
the chassis.
- Run the 8ga wire you got in your amp install kit
from your engine compartment to the back corner of the car where the
FPDM are mounted. There are different ways to connect this to your
electrical system. I choose to use the fuse holder that came with the
amp kit and connecting to the fuse box under the hood or you can go
directly to the positive terminal on the battery. Do not connect it to
electrical system yet just run the wire.
- If you got fuse holders that came with 12ga wire
add a female terminal connector to one end and plug it into the 12v
"In" side of one relay. Repeat on the other fuse holder for
the other relay. Connect/solder both fuse holders to the 8ga wire you
just ran from the fuse box/battery.
- Plug in one of the corresponding Pink/Black
stripe or Dark Green/Yellow
stripe wires from the amp bypass (step 6 under amp bypass) into the
"switch" side of the relay. Repeat for other wire and
relay.
Summary
The harness is
now complete and ready to install in the car. Everything at this point
should be pretty self explanatory, the combined ground wire should go to
the chassis, the 12V "In" wires connect to the 8 ga wire from
the engine compartment, the 12ga Positive and Ground wires from the FPDM
plug go to your fuel pumps, the two FPDM plug ends go to the each FPDM
(obviously you have to add a second one), the bypass plug connects to the
factory FPDM plug end and the relays get mounted wherever it is most convenient
for you.
FPDM Harness Plug 1
Black
- Combines with other Ground wires and grounds to chassis.
Grey/Pink
stripe - 1st Fuel Pump +
Red/Black
stripe - 1st Fuel Pump Ground -
White/Red
stripe - combine with white/red stripe wire and connect to amp bypass
Light
Blue/Orange stripe - connects to amp
bypass
Pink/Black
stripe (or Dark Green/Yellow
stripe) - goes to 12V "Output" from relay 1
FPDM Harness Plug 2
Black
- Combines with other Ground wires and grounds to chassis.
Grey/Pink
stripe - 2nd Fuel Pump +
Red/Black
stripe - 2nd Fuel Pump Ground -
White/Red
stripe - combine with white/red stripe wire and connect to amp bypass
Light
Blue/Orange stripe - not needed, cut
or remove pin from plug
Pink/Black
stripe (or Dark Green/Yellow
stripe) - goes to 12V "Output" from relay 2
Amp Bypass
Light
Blue/Orange stripe - connects to
corresponding wire from FPDM Harness Plug 1
White/Red
stripe - connects to corresponding wires from both FPDM Harnesses
Pink/Black
stripe (or Dark Green/Yellow
stripe) - split this wire into two wires and connect to the
"switch" side of both relays
Relays
Ground
- combine both with Black ground wires from FPDM Harnesses and
ground to chassis.
12V
In - connects to inline fuse and combined and connected to 8ga wire from
fuse box or battery
12V
Out - connects to Pink/Black stripe
(or Dark Green/Yellow
stripe) wire for each FPDM Harness Plug
Switch
- connects to the corresponding Pink/Black
stripe (or Dark Green/Yellow
stripe) wire from the Amp Bypass
For
any questions regarding this tech article please visit our forums at www.modularrevolution.com/forums/forums.php
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Written
by: Bill Putnam Product
Manufacturer: NA Difficulty
Level:  Time:
1.5 - 2 Hours Tools:
Wire cutters, wire strippers/crimpers, soldiering iron, lighter, dental
pick or other long narrow pick. Parts:
(2) FPDM Plug Ends (Ford part# 3U2Z-14S411-SAA) (2)
Relays (1)
Mach 460 Amp Bypass Plug (1)
20 Feet of Red 12ga Wire (1)
20 Feet of Black 12ga Wire (1)
Amp Install Kit w/8ga Wire (2)
12ga fuse holders and 15amp fuses (1)
12ga ring terminal (8)
Female terminal connectors Solder Heat
shrink |
