set 1 2 JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

DESCRIPTION - CONNECTOR, GROUND AND
SPLICE INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as
follows:
²In-line connectors located in the engine compart-
ment are C100 series numbers
²In-line connectors located in the Instrument
Panel area are C200 series numbers.
²In-line connectors located in the body are C300
series numbers.
²Jumper harness connectors are C400 series
numbers.
²Grounds and ground connectors are identified
with a ªGº and follow the same series numbering as
the in-line connectors.
²Splices are identified with an ªSº and follow the
same series numbering as the in-line connectors.
²Component connectors are identified by the com-
ponent name instead of a number. Multiple connec-
tors on a component use a C1, C2, etc. identifier.
LOCATIONS
Section 8W-91 contains connector/ground/splice
location illustrations. The illustrations contain the
connector name (or number)/ground number/splice
number and component identification. Connector/
ground/splice location charts in section 8W-91 refer-
ence the figure numbers of the illustrations.
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component. The abbre-
viation N/S means Not Shown in the illustrations
WARNING
WARNINGS - GENERAL
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.
²Jumper Wire - This is a test wire used to con-
nect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a cir-
cuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
WJ8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7
WIRING DIAGRAM INFORMATION (Continued)

STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the suspected fused circuits.
(2) Replace the blown fuse.
(3) Supply power to the fuse by turning ON the
ignition switch or re-connecting the battery.
(4) Start connecting or energizing the items in the
fuse circuit one at a time. When the fuse blows the
circuit with the short to ground has been isolated.
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 9).
(2) Connect the other lead of the voltmeter to the
other side of the switch, component or circuit.
(3) Operate the item.
(4) The voltmeter will show the difference in volt-
age between the two points.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 9 TESTING FOR VOLTAGE DROP
PROBING TOOL PACKAGE 6807
TERMINAL PICK TOOL SET 6680
TERMINAL REMOVING TOOLS 6932 AND 8638
TERMINAL REMOVING TOOL 6934
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATIONWJ
WIRING DIAGRAM INFORMATION (Continued)

8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch................. 8W-42
A/C Pressure Transducer................ 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Accessory Delay Relay.................. 8W-64
Adjustable Pedals..................... 8W-30
Airbags............................. 8W-43
Ambient Temperature Sensor............ 8W-45
Antennas............................ 8W-47
Ash Receiver Lamp.................... 8W-44
Auto Shut Down Relay................. 8W-30
Automatic Day/Night Mirror............. 8W-49
Automatic Headlamp Light Sensor/VTSS
LED.............................. 8W-39
Automatic Zone Control Module.......... 8W-42
Back-Up Lamp Relay................... 8W-51
Battery Temperature Sensor............. 8W-30
Battery............................. 8W-20
Blend Door Motor/Actuator.............. 8W-42
Blower Motor......................... 8W-42
Body Control Module................... 8W-45
Boost Pressure Sensor.................. 8W-30
Brake Lamp Switch.................... 8W-33
Camshaft Position Sensor............... 8W-30
Capacitors........................... 8W-30
Cargo Lamp.......................... 8W-44
Center High Mounted Stop Lamp......... 8W-51
Cigar Lighter......................... 8W-41
Circuit Breakers...................... 8W-12
Clockspring.................. 8W-33, 41, 43, 47
Coil On Plugs......................... 8W-30
Coil Rail............................. 8W-30
Combination Flasher................... 8W-52
Compact Disc Changer.................. 8W-47
Controller Antilock Brake............... 8W-35
Coolant Level Sensor................... 8W-45
Courtesy Lamps....................... 8W-44
Crankcase Heater..................... 8W-30
Crankshaft Position Sensor.............. 8W-30
Cylinder Lock Switches................. 8W-61
Data Link Connector................... 8W-18
Diagnostic Junction Port................ 8W-18
EGR Solenoid......................... 8W-30
Electric Brake........................ 8W-54
Electronic Speed Control Servo........... 8W-33
Engine Control Module................. 8W-30
Engine Coolant Temperature Sensor...... 8W-30
Engine Oil Pressure Sensor.............. 8W-30
Engine Starter Motor................... 8W-21
EVAP/Purge Solenoid................... 8W-30
Fog Lamps........................ 8W-50, 51
Fuel Injectors......................... 8W-30
Fuel Pressure Sensor................... 8W-30Component Page
Fuel Pressure Solenoid................. 8W-30
Fuel Pump........................... 8W-30
Fuel Tank Module..................... 8W-30
Fuses............................ 8W-10, 12
Fusible Link....................... 8W-10, 20
Grounds............................. 8W-15
Generator......................... 8W-20, 30
Glove Box Lamp...................... 8W-44
Glow Plugs........................... 8W-30
Headlamp Leveling Motor............... 8W-50
Heated Seats......................... 8W-63
High Beam Headlamps................. 8W-50
Hood Ajar Switch...................... 8W-39
Horns............................... 8W-41
Hydraulic Cooling Module............ 8W-30, 42
Idle Air Control Motor.................. 8W-30
Ignition Switch....................... 8W-10
Impact Sensors....................... 8W-43
Input Speed Sensor.................... 8W-31
Instrument Cluster.................... 8W-40
Intake Air Temperature Sensor........... 8W-30
Intake Port Swirl Actuator.............. 8W-30
Intrusion Transceiver Module............ 8W-49
Junction Block........................ 8W-12
Knock Sensor......................... 8W-30
Lamp Assemblies................... 8W-51, 52
Leak Detection Pump.................. 8W-30
License Lamps........................ 8W-51
Liftgate............................. 8W-61
Line Pressure Sensor................... 8W-31
Low Beam Headlamps.................. 8W-50
Low Beam Relay...................... 8W-50
Low Beam/Daytime Running Lamp Relay . . . 8W-50
Lumbar Motor........................ 8W-63
Lumbar Switch....................... 8W-63
Manifold Absolute Pressure Sensor........ 8W-30
Manual Temperature Control............. 8W-42
Mass Air Flow Sensor.................. 8W-30
Memory Set Switch................. 8W-62, 63
Mode Door Motor/Actuator............... 8W-42
Multi-Function Switch............... 8W-50, 53
Output Speed Sensor................... 8W-31
Overhead Map/Courtesy Lamp........... 8W-44
Oxygen Sensors....................... 8W-30
Park Brake Switch..................... 8W-40
Park Lamp........................... 8W-50
Park/Neutral Position Switch............ 8W-31
Park/Turn Signal Lamps................ 8W-50
Power Amplifier....................... 8W-47
Power Connector...................... 8W-41
Power Distribution Center............... 8W-10
Power Mirrors........................ 8W-62
WJ8W-02 COMPONENT INDEX 8W - 02 - 1

8W-62 POWER MIRRORS
Component Page
Automatic Day/Night Mirror............ 8W-62-6
Body Control Module............... 8W-62-2, 3
Diagnostic Junction Port............. 8W-62-2, 3
Driver Door Module............ 8W-62-2, 3, 4, 6
Driver Front Door Courtesy Lamp....... 8W-62-4
Driver Power Mirror.................. 8W-62-6
G300.............................. 8W-62-2Component Page
G301.............................. 8W-62-3
Junction Block.................... 8W-62-2, 3
Memory Set Switch................... 8W-62-4
Passenger Door Module............ 8W-62-2, 3, 5
Passenger Front Door Courtesy Lamp.... 8W-62-5
Passenger Power Mirror............... 8W-62-5
WJ8W-62 POWER MIRRORS 8W - 62 - 1

8W-63 POWER SEATS
Component Page
Body Control Module................ 8W-63-12
Circuit Breaker No. 2 (JB).... 8W-63-2, 3, 4, 10, 11
Driver Door Module.................. 8W-63-3
Driver Heated Seat Back............ 8W-63-6, 7
Driver Heated Seat Cushion.......... 8W-63-6, 7
Driver Heated Seat Switch............ 8W-63-12
Driver Lumbar Motor............. 8W-63-10, 11
Driver Lumbar Switch............. 8W-63-10, 11
Driver Power Seat Front Riser Motor . . . 8W-63-2, 5
Driver Power Seat Front Riser
Motor Sensor..................... 8W-63-8
Driver Power Seat Horizontal Motor.... 8W-63-2, 5
Driver Power Seat Horizontal
Motor Sensor.................... 8W-63-8, 9
Driver Power Seat Rear Riser Motor . . . 8W-63-2, 5
Driver Power Seat Rear Riser
Motor Sensor..................... 8W-63-8
Driver Power Seat Recliner Motor..... 8W-63-2, 5
Driver Power Seat Recliner
Motor Sensor.................... 8W-63-8, 9Component Page
Driver Power Seat Switch............ 8W-63-2, 5
Fuse 20........................... 8W-63-12
G200............................. 8W-63-12
G300.................... 8W-63-3, 4, 5, 10, 11
G301.................. 8W-63-2, 3, 4, 5, 10, 11
Junction Block.......... 8W-63-2, 3, 4, 10, 11, 12
Memory Set Switch................... 8W-63-3
Passenger Heated Seat Back......... 8W-63-6, 7
Passenger Heated Seat Cushion....... 8W-63-6, 7
Passenger Heated Seat Switch......... 8W-63-12
Passenger Lumbar Motor.......... 8W-63-10, 11
Passenger Lumbar Switch.......... 8W-63-10, 11
Passenger Power Seat Front
Riser Motor....................... 8W-63-4
Passenger Power Seat Horizontal Motor . . . 8W-63-4
Passenger Power Seat Rear
Riser Motor....................... 8W-63-4
Passenger Power Seat Recliner Motor.... 8W-63-4
Passenger Power Seat Switch........... 8W-63-4
Seat Module.............. 8W-63-3, 5, 6, 7, 8, 9
WJ8W-63 POWER SEATS 8W - 63 - 1

DRIVER DOOR MODULE C3 - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 BK MEMORY SWITCH RETURN
2 BR MEMORY SWITCH MUX
3 OR MEMORY SET INDICATOR DRIVER
4 GY SWITCH ILLUMINATION DRIVER
DRIVER FRONT DOOR COURTESY LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 M21 20PK/DG COURTESY LAMP DRIVER
2 L121 20BK/RD COURTESY LAMP GROUND
DRIVER FRONT POWER WINDOW MOTOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Q21 16WT DRIVER WINDOW DRIVER (DOWN)
2 Q11 16LB DRIVER WINDOW DRIVER (UP)
DRIVER HEATED SEAT BACK (PREMIUM I/III)-3WAY
CAV CIRCUIT FUNCTION
1 P88 16BK/BR HEATED SEAT DRIVER
2 Z6 16BK/YL GROUND
3- -
DRIVER HEATED SEAT CUSHION (PREMIUM I/III)-4WAY
CAV CIRCUIT FUNCTION
1 P131 16BK/OR DRIVER SEAT HEATER B(+) DRIVER
2 P88 16BK/BR HEATED SEAT DRIVER
3 P135 20LB/BK DRIVER SEAT TEMPERATURE SENSOR INPUT
4 P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
WJ8W-80 CONNECTOR PIN-OUT 8W - 80 - 69

8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2
CIGAR LIGHTER OUTLET
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET.............................2
CIGAR LIGHTER OUTLET DOOR SPRING
REMOVAL.............................3
INSTALLATION..........................3
IOD FUSE
DESCRIPTION..........................3
OPERATION............................4
REMOVAL.............................4
INSTALLATION..........................4
JUNCTION BLOCK
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
POWER DISTRIBUTION CENTER
DESCRIPTION..........................7
OPERATION............................8
REMOVAL.............................8
DISASSEMBLY
POWER DISTRIBUTION CENTER
DISASSEMBLY........................9ASSEMBLY
POWER DISTRIBUTION CENTER
ASSEMBLY..........................11
INSTALLATION.........................12
POWER OUTLET
DESCRIPTION - FRONT POWER OUTLET....12
OPERATION - FRONT POWER OUTLET......12
DIAGNOSIS AND TESTING - POWER OUTLET . 12
REMOVAL.............................13
INSTALLATION.........................13
POWER OUTLET RELAY
DESCRIPTION.........................13
OPERATION...........................14
DIAGNOSIS AND TESTING - POWER OUTLET
RELAY..............................14
REMOVAL.............................15
INSTALLATION.........................15
IOD WIRE HARNESS CONNECTOR
DESCRIPTION.........................15
OPERATION...........................15
FUSE COVER
REMOVAL.............................16
INSTALLATION.........................16
REAR POWER OUTLET
DESCRIPTION - REAR POWER OUTLET.....16
OPERATION - REAR POWER OUTLET.......17
DIAGNOSIS AND TESTING - REAR POWER
OUTLET............................17
REMOVAL.............................17
INSTALLATION.........................18
POWER DISTRIBUTION
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists of the following components:
²Power Distribution Center (PDC)
²Junction Block (JB)
²Power Outlets
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Bus bars
²Cartridge fuses²Circuit splice blocks
²Flashers
²Fusible links
²Standard and Micro-Relays
Following are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components. Refer to Wir-
ing Diagrams for complete circuit diagrams.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the standard and optional factory-in-
stalled electrical and electronic powertrain, chassis,
safety, security, comfort and convenience systems. At
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 1

JUNCTION BLOCK
DESCRIPTION
An electrical Junction Block (JB) is concealed
beneath the driver side of the instrument panel in
the passenger compartment of the vehicle (Fig. 3).
The JB combines the functions previously provided
by a separate fuseblock module and relay center. The
JB serves to simplify and centralize numerous elec-
trical components, as well as to distribute electrical
current to many of the accessory systems in the vehi-
cle. It also eliminates the need for numerous splice
connections. The JB houses up to thirty-three blade-
type mini fuses, up to two blade-type automatic
resetting circuit breakers, the electronic combination
flasher, the Daytime Running Lamp (DRL) module
(Canada only) and up to twelve International Stan-
dards Organization (ISO) relays (three standard-type
and nine micro-type). The JB also incorporates an
integral connector and mounting for the Body Con-
trol Module (BCM). The BCM is secured with four
screws directly to the dash panel side of the JB.
Refer toBody Control Modulein Electronic Con-
trol Modules for additional information covering the
BCM.
The molded plastic JB housing has integral mounts
that are secured with two screws and two snap
retainers to the instrument panel steering column
support bracket behind the instrument panel steer-ing column opening cover. The JB is concealed above
the molded plastic instrument panel fuse cover. Inte-
gral latches molded into the fuse cover secure it the
JB, the BCM and the 16-way data link connector tab
of the instrument panel steering column support
bracket. The fuse cover can be pulled downward to
disengage the latches and provide service access to
all of the fuses, relays and wire harness connectors of
the JB. The fuse cover has a fuse puller and spare
fuses secured to its upper surface. Refer toInstru-
ment Panel Fuse Coverin Body for additional ser-
vice information.
The JB unit cannot be repaired and is only ser-
viced as an assembly. If any internal circuit or the JB
housing is faulty or damaged, the entire JB unit
must be replaced. The BCM is available for separate
service replacement.
OPERATION
All of the circuits entering and leaving the Junc-
tion Block (JB) do so through up to five wire harness
connectors, which are connected to the JB through
integral connector receptacles molded into the JB
housing. Internal connection of all of the JB circuits
is accomplished by a printed circuit board. There are
also two separate wire harness connections to con-
nector receptacles that are integral to the BCM.
Refer toJunction Blockin Wiring Diagrams for
additional information and the location of complete
JB circuit diagrams.
REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the fuse cover from the bottom of the
Junction Block (JB).
(3) Remove the steering column opening cover
from the instrument panel. Refer toSteering Col-
umn Opening Coverin Body for the location of
steering column opening cover removal procedures.
Fig. 3 Junction Block Location
1 - REAR LATCHES
2 - JUNCTION BLOCK AND BODY CONTROL MODULE UNIT
3 - INSTRUMENT PANEL FUSE COVER
4 - SIDE LATCH
5 - FRONT LATCHES
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 5

(5) Reconnect the right and left body wire harness
bulkhead connectors to the connector receptacles
located near the center of the JB.
(6) Install and tighten the screws that secure the
right and left body wire harness bulkhead connectors
to the connector receptacles located near the center
of the JB. Tighten the screws to 2.2 N´m (20 in. lbs.).
(7) Reconnect the fused B(+) and the IOD wire
harness connectors to the connector receptacles
located near the bottom of the JB.
(8) Reach behind the JB to reconnect the instru-
ment panel wire harness bulkhead connector to the
connector receptacle located near the top of the JB.
(9) Install and tighten the screw that secures the
instrument panel wire harness bulkhead connector to
the connector receptacle located near the top of the
JB. Tighten the screw to 2.2 N´m (20 in. lbs.).
(10)
Reach behind the JB to reconnect the two
instrument panel wire harness connectors to the BCM
connector receptacles located near the bottom of the JB.
(11) Install the steering column opening cover onto
the instrument panel. Refer toSteering Column
Opening Coverin Body for the location of the steer-
ing column opening cover installation procedures.
(12)
Install the fuse cover onto the bottom of the JB.
(13) Reconnect the battery negative cable.
POWER DISTRIBUTION
CENTER
DESCRIPTION
All of the electrical current distributed throughout
this vehicle is directed through the standard equip-ment Power Distribution Center (PDC) (Fig. 7). The
molded plastic PDC housing is located in the right
front corner of the engine compartment, between the
battery and the right front inner fender shield. The
PDC houses up to fifteen maxi-type cartridge fuses,
which replace all in-line fusible links. The PDC also
houses up to thirteen blade-type mini fuses, and up
to ten International Standards Organization (ISO)
relays (two standard-type and eight micro-type).
The PDC housing is secured in the engine compart-
ment at three points. Integral mounts on both sides of
the PDC housing engage and latch to stanchions that
are integral to the molded plastic battery support. The
PDC is integral to the right headlamp and dash wire
harness, which exits from the bottom of the PDC hous-
ing. The PDC housing has a molded plastic cover that
includes two integral latches at the front and pivot
hooks at the back that snap over a hinge pin on the
rear of the PDC housing. The PDC cover is easily
opened or removed for service access and has a conve-
nient fuse and relay layout map integral to the inside
surface of the cover to ensure proper component identi-
fication. A fuse puller is also stored on the inside of the
PDC cover.
The PDC cover, the PDC housing lower cover, the
PDC relay wedges, the PDC relay cassettes and the
PDC B(+) terminal stud module are available for ser-
vice replacement. The PDC main housing unit, the
fuse wedges and the bus bars cannot be repaired and
Fig. 6 Junction Block
1 - SCREW (2)
2 - DRIVER SIDE COURTESY LAMP
3 - JUNCTION BLOCK
4 - 16 WAY DATA LINK CONNECTOR
Fig. 7 Power Distribution Center Location
1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER
4 - COVER
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 7
JUNCTION BLOCK (Continued)

(9) Remove the PDC and the right headlamp and
dash wire harness from the engine compartment as a
unit.
DISASSEMBLY
POWER DISTRIBUTION CENTER DISASSEMBLY
PDC HOUSING LOWER COVER REMOVAL
The Power Distribution Center (PDC) cover, the
PDC housing lower cover, the PDC relay wedges, the
PDC relay cassettes and the PDC B(+) terminal stud
module are available for service replacement. The
PDC cover can be simply unlatched and removed
from the PDC housing without the PDC being
removed or disassembled. Service of the remaining
PDC components requires that the PDC be removed
from its mounting and disassembled. Refer toWiring
Repairin Wiring Diagrams for the location of the
wiring repair procedures.
(1) Remove the battery from the battery support.
Refer toBattery Systemfor the location of the bat-
tery removal procedures.
(2) Unlatch and remove the cover from the PDC.
(3) Remove the two nuts that secure the two-holed
eyelet of the battery wire harness PDC take out to
the B(+) terminal studs near the front of the PDC.
(4) Remove the battery wire harness PDC take out
eyelet from the two PDC B(+) terminal studs.
(5) Disengage the latches on the PDC housing
mounts from the tabs on the PDC mounting stan-
chions on the battery support, and pull the PDC
housing upward to disengage the mounts from the
stanchions.
(6) Where the right headlamp and dash wire har-
ness exits the PDC, remove the tape that secures the
wire harness to the trough formation on the PDC
housing lower cover.
(7) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the latches on each side
and the front of the PDC housing that secure the
housing lower cover to the PDC and remove the
housing lower cover (Fig. 10).
PDC B+ TERMINAL MODULE REMOVAL
The Power Distribution Center (PDC) cover, the
PDC housing lower cover, the PDC relay wedges, the
PDC relay cassettes and the PDC B(+) terminal stud
module are available for service replacement. The
PDC cover can be simply unlatched and removed
from the PDC housing without the PDC being
removed or disassembled. Service of the remaining
PDC components requires that the PDC be removed
from its mounting and disassembled. Refer toWiring
Repairin Wiring Diagrams for the location of the
wiring repair procedures.(1) Remove the PDC housing lower cover.
(2) From the top of the PDC housing, use a small
screwdriver or a terminal pick tool (Special Tool Kit
6680) to release the two latches that secure the B(+)
terminal module in the PDC.
(3) Gently and evenly press the two B(+) terminal
studs down through the bus bar in the PDC.
(4) From the bottom of the PDC housing, remove
the B(+) terminal module from the PDC.
PDC RELAY WEDGE REMOVAL
The Power Distribution Center (PDC) cover, the
PDC housing lower cover, the PDC relay wedges, the
PDC relay cassettes and the PDC B(+) terminal stud
module are available for service replacement. The
PDC cover can be simply unlatched and removed
from the PDC housing without the PDC being
removed or disassembled. Service of the remaining
PDC components requires that the PDC be removed
from its mounting and disassembled. Refer toWiring
Repairin Wiring Diagrams for the location of the
wiring repair procedures.
(1) Remove the PDC housing lower cover.
(2) Remove each of the relays from the PDC relay
wedge to be removed.
(3) From the bottom of the PDC housing, use a
small screwdriver or a terminal pick tool (Special
Fig. 10 PDC Housing Lower Cover Remove/Install -
Typical
1 - TROUGH FORMATION
2 - LATCHES (5)
3 - PDC HOUSING LOWER COVER
4 - WIRE HARNESS
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 9
POWER DISTRIBUTION CENTER (Continued)