wire diagram JEEP GRAND CHEROKEE 2002 WJ / 2.G Manual PDF

²Ohmmeter - Used to check the resistance
between two points of a circuit. Low or no resistance
in a circuit means good continuity.
CAUTION: Most of the electrical components used
in today's vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 -
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicle's
electrical system can cause damage to the equip-
ment and provide false readings.
²Probing Tools - These tools are used for probing
terminals in connectors (Fig. 5). Select the proper
size tool from Special Tool Package 6807, and insert
it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused
by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a
problem. Before condemning a component or wiring
assembly, check the following items.
²Connectors are fully seated
²Spread terminals, or terminal push out
²Terminals in the wiring assembly are fully
seated into the connector/component and locked into
position
²
Dirt or corrosion on the terminals. Any amount of
corrosion or dirt could cause an intermittent problem
²Damaged connector/component casing exposing
the item to dirt or moisture
²Wire insulation that has rubbed through causing
a short to ground
²Some or all of the wiring strands broken inside
of the insulation
²Wiring broken inside of the insulation
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The stepsare listed and explained below. Always check for non-
factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem area.
(6) Verify the proper operation. For this step,
check for proper operation of all items on the
repaired circuit. Refer to the wiring diagrams.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 6) is used to indicate this. When handling
any component with this symbol, comply with the fol-
lowing procedures to reduce the possibility of electro-
static charge build up on the body and inadvertent
discharge into the component. If it is not known
whether the part is ESD sensitive, assume that it is.
(1) Always touch a known good ground before han-
dling the part. This should be repeated while han-
dling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written procedure.
(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part form it's protective
packing until it is time to install the part.
(5) Before removing the part from it's pakage,
ground the pakage to a known good ground on the
vehicle.
Fig. 5 PROBING TOOL
1 - SPECIAL TOOL 6801
2 - PROBING END
Fig. 6 ELECTROSTATIC DISCHARGE SYMBOL
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATIONWJ
WIRING DIAGRAM INFORMATION (Continued)

CONNECTOR
REMOVAL
(1) Disconnect battery.
(2) Release Connector Lock (Fig. 10).
(3) Disconnect the connector being repaired from
its mating half/component.
(4) Remove the dress cover (if applicable) (Fig. 10).
(5) Release the Secondary Terminal Lock, if
required (Fig. 11).
(6) Position the connector locking finger away from
the terminal using the proper special tool. Pull on
the wire to remove the terminal from the connector
(Fig. 12).
INSTALLATION
(1) Insert the removed terminal in the same cavity
on the repair connector.
(2) Repeat steps for each terminal in the connec-
tor, being sure that all wires are inserted into the
proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.
(3) When the connector is re-assembled, the sec-
ondary terminal lock must be placed in the locked
position to prevent terminal push out.
(4) Replace dress cover (if applicable).
(5) Connect connector to its mating half/compo-
nent.
(6) Connect battery and test all affected systems.
Fig. 10 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
WJ8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11

DIODE
REMOVAL
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 13).
INSTALLATION
(1) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(2) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow (Fig. 13).
(3) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(4) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(5) Re-connect the battery and test affected sys-
tems.
TERMINAL
REMOVAL
(1) Follow steps for removing terminals described
in the connector removal section.
(2) Cut the wire 6 inches from the back of the con-
nector.
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the wire being
repaired.
(2) Cut the repair wire to the proper length and
remove one±half (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness (see
wire splicing procedure).
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
nent.
(6) Re-tape the wire harness starting at 1±1/2
inches behind the connector and 2 inches past the
repair.
(7) Connect battery and test all affected systems.
Fig. 13 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATIONWJ

WIRE
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the cor-
rect gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wire that needs to be spliced.
(2) Place a piece of adhesive lined heat shrink tub-
ing on one side of the wire. Make sure the tubing will
be long enough to cover and seal the entire repair
area.
(3) Place the strands of wire overlapping each
other inside of the splice clip (Fig. 14).
(4) Using crimping tool, Mopar p/n 05019912AA,
crimp the splice clip and wires together (Fig. 15).(5) Solder the connection together using rosin core
type solder only (Fig. 16).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing (Fig. 17).
Fig. 14 SPLICE BAND
1 - SPLICE BAND
Fig. 15 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 16 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 17 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
WJ8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15

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

(4) Reach behind the JB to disconnect the two
instrument panel wire harness connectors from the
Body Control Module (BCM) connector receptacles
located near the bottom of the JB (Fig. 4).
(5) Reach behind the JB to remove the screw that
secures the instrument panel wire harness bulkhead
connector to the connector receptacle located near the
top of the JB and disconnect the connector.
(6) Disconnect the fused B(+) and the IOD wire
harness connectors from the connector receptacles
located near the bottom of the JB (Fig. 5).
(7) Remove the screws that secure the right and
left body wire harness bulkhead connectors to the
connector receptacles located near the center of the
JB and disconnect the connectors.
(8) Remove the two screws that secure the JB to
the instrument panel steering column support
bracket (Fig. 6).
(9) To disengage the two snap clips that secure the
top of the JB to the instrument panel steering col-
umn support bracket, grasp the bottom of the junc-
tion block firmly with both hands and pull it
downward sharply.
(10) Remove the JB from the instrument panel
steering column support bracket.
INSTALLATION
NOTE: If the Junction Block (JB) is being replaced
with a new unit, be certain to transfer each of the
optional fuses, circuit breakers and relays from thefaulty JB to the proper cavities of the replacement
JB. Refer to Junction Block in Wiring Diagrams for
the location of complete circuit diagrams and cavity
assignments for the JB. The Body Control Module
(BCM) must also be transferred to the new JB.
Refer to Body Control Module in Electronic Control
Modules for the location of the BCM removal and
installation procedures.
(1)
Position the JB into its mounting location on the
instrument panel steering column support bracket.
(2) Align the snap clips at the top of the JB with
the mounting holes in the instrument panel steering
column support bracket.
(3) Grasp the bottom of the JB firmly with both
hands and push it upward sharply to engage the two
snap clips that secure the top of the JB to the instru-
ment panel steering column support bracket.
(4)
Install and tighten the two screws that secure the
JB to the instrument panel steering column support
bracket. Tighten the screws to 2.2 N´m (20 in. lbs.).
Fig. 4 Junction Block Connections
1 - SCREW
2 - JUNCTION BLOCK
3 - BULKHEAD CONNECTOR
4 - BODY CONTROL MODULE
5 - INSTRUMENT PANEL WIRE HARNESS CONNECTORS
Fig. 5 Junction Block Connections
1 - SNAP CLIPS
2 - SCREW
3 - CONNECTOR
4 - LEFT BODY WIRE HARNESS
5 - IOD CONNECTOR
6 - FUSED B+ CONNECTOR
7 - RIGHT BODY WIRE HARNESS
8 - SCREW
9 - CONNECTOR
10 - JUNCTION BLOCK
8W - 97 - 6 8W-97 POWER DISTRIBUTIONWJ
JUNCTION BLOCK (Continued)

are only serviced as a unit with the right headlamp
and dash wire harness. If the PDC main housing
unit, fuse wedges or the bus bars are faulty or dam-
aged, the right headlamp and dash wire harness unit
must be replaced.
OPERATION
All of the current from the battery and the generator
output enters the PDC through two cables and a single
two-holed eyelet that is secured with nuts to the two
PDC B(+) terminal studs just inside the front end of the
PDC housing. The PDC cover is unlatched and opened
to access the battery and generator output connection
B(+) terminal studs, the fuses or the relays. Internal
connection of all of the PDC circuits is accomplished by
an intricate combination of hard wiring and bus bars.
Refer toPower Distribution
in Wiring Diagrams for
the location of complete PDC circuit diagrams.
REMOVAL
The Power Distribution Center (PDC) main housing
unit, the PDC fuse wedges and the PDC bus bars can-
not be repaired and are only serviced as a unit with the
right headlamp and dash wire harness. If the PDC
main housing unit, the fuse wedges or the bus bars are
faulty or damaged, the entire PDC and right headlamp
and dash wire harness unit must be replaced.
(1)Disconnect and isolate the battery negative cable.
(2) Disconnect each of the right headlamp and
dash wire harness connectors. Refer toConnector
Locationsin Wiring Diagrams for the location of
more information on the right headlamp and dash
wire harness connector locations.
(3) Remove all of the fasteners that secure each of
the right headlamp and dash wire harness ground
eyelets to the vehicle body and chassis components.
Refer toConnector Locationsin Wiring Diagrams
for the location of more information on the ground
eyelet locations.
(4) Disengage each of the retainers that secure the
right headlamp and dash wire harness to the vehicle
body and chassis components. Refer toConnector
Locationsin Wiring Diagrams for the location of
more information on the right headlamp and dash
wire harness retainer locations.
(5) Unlatch and open the PDC cover.
(6) Remove the two nuts that secure the two-holed
eyelet of the battery wire harness PDC take outs to
the PDC B(+) terminal studs (Fig. 8).
(7) Remove the battery wire harness PDC take out
eyelet from the B(+) terminal studs.
(8) Disengage the latches on the PDC housing
mounts from the tabs on the PDC mounting stan-
chions of the battery support, and pull the PDC
housing upward to disengage the mounts from the
stanchions (Fig. 9).
Fig. 8 Power Distribution Center Connections
1 - PDC COVER
2 - NUT (2)
3 - EYELET
4 - B(+) TERMINAL STUDS
Fig. 9 Power Distribution Center Remove/Install
1 - POWER DISTRIBUTION CENTER
2 - MOUNTS
3 - STANCHIONS (3)
4 - BATTERY SUPPORT
8W - 97 - 8 8W-97 POWER DISTRIBUTIONWJ
POWER DISTRIBUTION CENTER (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)

CAUTION: Do not remove the wiring and terminals
from the terminal cavities of the faulty PDC relay
cassette at this time. Refer to the Assembly proce-
dure that follows for the proper procedures for
transferring the wiring and terminals to the replace-
ment PDC relay cassette.
ASSEMBLY
POWER DISTRIBUTION CENTER ASSEMBLY
PDC B(+) TERMINAL MODULE INSTALLATION
(1) From the bottom of the PDC housing, align and
insert the B(+) terminal module into the PDC.
(2) From the bottom of the PDC housing, align and
insert the two studs of the PDC B(+) terminal mod-
ule through the bus bar in the PDC.
(3) From the bottom of the PDC housing, press the
B(+) terminal module gently and evenly into the PDC
until both of the latches are fully engaged.
(4) Install the PDC housing lower cover.
RELAY WEDGE INSTALLATION
(1) From the top of the PDC housing, align and
insert the PDC relay wedge latch arms into the cor-
rect cavities in the relay cassette.
(2) Gently and evenly press the PDC relay wedge
down into the relay cassette until both of the latches
are fully engaged.
(3) Install each of the removed relays into the
proper cavities of the PDC relay wedge.
(4) Install the PDC housing lower cover.
RELAY CASSETTE INSTALLATION
(1) Move the faulty PDC relay cassette with its
wiring away from the bottom of the PDC housing far
enough to allow the replacement relay cassette to be
installed into the PDC.
(2) Using the faulty relay cassette as a guide, be
certain that the replacement relay cassette is cor-
rectly oriented before installing it into the PDC hous-
ing.
(3) From the bottom of the PDC housing, align and
insert the replacement relay cassette into the PDC.
Press the relay cassette up into the PDC until both
of the latches are fully engaged.
CAUTION: Proper care must be taken to be certain
that the wiring and terminals from the faulty PDC
relay cassette are installed in the correct terminal
cavities of the replacement relay cassette. To pre-
vent mistakes it is recommended that the wiring
and terminals be removed from the faulty relay cas-
sette one cavity at a time, repaired or spliced as
necessary, then installed securely into the correctcavity of the replacement relay cassette. If you are
not absolutely certain into which cavity a terminal
should be installed, refer to Power Distribution in
the index of this service manual for the location of
complete circuit diagrams covering the PDC.
(4) While pulling gently on the wire from the bot-
tom of the faulty PDC relay cassette, use a terminal
pick tool (Special Tool Kit 6680) from the top of the
relay cassette to release the latch that secures the
terminal in the relay cassette terminal cavity (Fig.
14).
(5) From the bottom of the faulty PDC relay cas-
sette, remove the wire and terminal from the relay
cassette terminal cavity.
(6) Make all necessary repairs and splices to the
wire for the removed terminal. Refer toWiring
Repairin Wiring Diagrams for the location of the
wiring repair procedures.
(7) From the bottom of the PDC housing, align and
insert the removed wire and terminal into the correct
terminal cavity of the replacement relay cassette.
Push the wire and terminal up into the relay cassette
terminal cavity until it is fully engaged by the latch.
(8) Repeat Step 4, Step 5, Step 6 and Step 7 one
wire and terminal at a time until each of the wires
and terminals have been transferred from the faulty
PDC relay cassette into the replacement relay cas-
sette.
(9) Install the PDC relay wedge into the replace-
ment PDC relay cassette.
Fig. 14 PDC Relay Cassette Terminal Remove/Install
- Typical
1 - TERMINAL CAVITIES (TYPICAL)
2 - PDC RELAY CASSETTE (TYPICAL)
3 - TERMINAL LATCHES (TYPICAL)
4 - FROM SPECIAL TOOL KIT 6680
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 11
POWER DISTRIBUTION CENTER (Continued)