Jeep Cherokee (XJ): Removal and installation

Power distribution center

The Power Distribution Center (PDC) main housing unit, the PDC fuse wedges, the PDC fuse cassette and the PDC bus bars cannot be repaired and are only serviced as a unit with the headlamp and dash wire harness. If the PDC main housing unit, the fuse wedge, the fuse cassette or the bus bars are faulty or damaged, the entire PDC and headlamp and dash wire harness unit must be replaced.

REMOVAL

(1) Disconnect and isolate the battery negative cable.

(2) Disconnect each of the headlamp and dash wire harness connectors. Refer to Connector Locations in the index of this service manual for the location of more information on the headlamp and dash wire harness connector locations.

(3) Remove all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. Refer to Connector Locations in the index of this service manual for the location of more information on the ground eyelet locations.

(4) Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. Refer to Connector Locations in the index of this service manual for the location of more information on the headlamp and dash wire harness retainer locations.

(5) Unlatch and remove the B(+) terminal stud cover from the end of the PDC (Fig. 4).

(6) Remove the nut that secures the eyelets of the battery wire harness PDC take outs to the PDC B(+) terminal stud.

Fig. 4 Power Distribution Center Connections

1 - COVER
2 - NUT
3 - POWER DISTRIBUTION CENTER
4 - BATTERY
5 - BATTERY WIRE HARNESS PDC TAKE-OUTS

(7) Remove the battery wire harness PDC take out eyelets from the B(+) terminal stud.

(8) Disengage the latches on the PDC mounting bracket from the tabs on the PDC housing, and pull the PDC housing upward to disengage the mounting slots from the stanchions of the mounting bracket (Fig. 5).

(9) Remove the PDC and the headlamp and dash wire harness from the engine compartment as a unit.

(10) Remove the two screws that secure the PDC mounting bracket to the right front inner fender (Fig.

6).

(11) Remove the PDC mounting bracket from the right front inner fender.

INSTALLATION

NOTE: If the PDC is being replaced with a new unit, be certain to transfer each of the fuses and relays from the faulty PDC to the proper cavities of the replacement PDC. Refer to Power Distribution in the index of this service manual for the location of complete PDC circuit diagrams and cavity assignments.

(1) Position the PDC mounting bracket onto the right front inner fender.

(2) Install and tighten the two screws that secure the PDC mounting bracket to the right front inner fender. Tighten the screws to 8.1 N·m (72 in. lbs.).

Fig. 5 Power Distribution Center Remove/Install

1 - RIGHT FENDER
2 - POWER DISTRIBUTION CENTER
3 - BRACKET

Fig. 6 PDC Mounting Bracket Remove/Install

1 - RIGHT FRONT INNER FENDER
2 - PDC MOUNTING BRACKET
3 - SCREW

(3) Position the PDC and the headlamp and dash wire harness unit in the engine compartment.

(4) Engage the mounting slots on the PDC housing with the stanchions of the PDC mounting bracket and push the unit downward until the mounting bracket latches engage the mounting tabs on the PDC housing.

(5) Install the eyelets of the battery wire harness PDC take outs onto the PDC B(+) terminal stud.

(6) Install and tighten the nut that secures the eyelet of the battery wire harness PDC take outs to the B(+) terminal stud. Tighten the nut to 10.8 N·m (95 in. lbs.).

(7) Engage the tabs on the lower edge of the B(+) terminal stud cover in the slots on the PDC housing, then engage the latch on the top of the cover with the latch receptacle on the PDC housing.

(8) Engage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components. Refer to Connector Locations in the index of this service manual for the location of more information on the headlamp and dash wire harness retainer locations.

(9) Install all of the fasteners that secure each of the headlamp and dash wire harness ground eyelets to the vehicle body and chassis components. Refer to Connector Locations in the index of this service manual for the location of more information on the ground eyelet locations.

(10) Reconnect each of the headlamp and dash wire harness connectors. Refer to Connector Locations in the index of this service manual for the location of more information on the headlamp and dash wire harness connector locations.

(11) Reconnect the battery negative cable.

Ignition-off draw fuse

The Ignition-Off Draw (IOD) fuse is removed from Power Distribution Center (PDC) fuse cavity 16 (Fig.

7) when the vehicle is shipped from the assembly plant. Dealer personnel must install the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation.

NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Off position will usually correct the scrambled radio display condition.

REMOVAL

(1) Turn the ignition switch to the Off position.

(2) Unlatch and remove the cover from the PDC.

(3) Remove the IOD fuse from fuse cavity 16 of the PDC.

(4) Store the removed IOD fuse by inserting the terminal blades of the fuse into the plastic fuse holder formation that is molded into the underside of the PDC cover.

(5) Install and latch the cover onto the PDC.

Fig. 7 Ignition-Off Draw Fuse

1 - POWER DISTRIBUTION CENTER
2 - IGNITION-OFF DRAW FUSE

INSTALLATION

(1) Turn the ignition switch to the Off position.

(2) Unlatch and remove the cover from the PDC.

(3) Remove the stored IOD fuse from the plastic fuse holder formation that is molded into the underside of the PDC cover.

(4) Align the terminal blades of the IOD fuse with the terminal receptacles in fuse cavity 16 of the PDC.

(5) Use a thumb to press the IOD fuse firmly down into PDC fuse cavity 16.

(6) Install and latch the cover onto the PDC.

Junction block

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT 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 DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

REMOVAL

(1) Disconnect and isolate the battery negative cable.

(2) Remove the fuse access panel by unsnapping it from the right cowl side inner trim panel (Fig. 8).

Fig. 8 Right Cowl Side Inner Trim Remove/Install

1 - RIGHT FRONT DOOR SILL
2 - COWL SIDE TRIM PANEL
3 - SCREW
4 - SILL TRIM
5 - FUSE ACCESS PANEL
6 - PUSH-NUT

(3) Remove the push nut that secures the right cowl side inner trim panel to the mounting stud on the Junction Block (JB).

(4) Remove the screw located above the fuse access opening that secures the trim panel to the right cowl side inner panel.

(5) Remove the screw that secures the right cowl side inner trim panel and right front door sill trim to the door opening sill.

(6) Remove the trim from the right cowl side inner panel.

(7) Remove the screw that secures the lower instrument panel wire harness connector to the JB.

(8) Disconnect all of the wire harness connectors from the connector receptacles on the JB.

(9) Remove the three nuts that secure the JB to the mounting studs on the right cowl side inner panel (Fig. 9).

Fig. 9 Junction Block Remove/Install

1 - JUNCTION BLOCK
2 - STUD
3 - RIGHT COWL SIDE INNER PANEL
4 - NUT

(10) Remove the JB from the mounting studs on the right cowl side inner panel.

INSTALLATION

NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB. Refer to Junction Block in the index of this service manual for the location of complete circuit diagrams and cavity assignments for the JB.

(1) Position the JB onto the mounting studs located on the right cowl side inner panel.

(2) Install and tighten the three nuts that secure the JB to the mounting studs on the right cowl side inner panel. Tighten the nuts to 2.7 N·m (24 in. lbs.).

(3) Reconnect all of the wire harness connectors to the proper connector receptacles on the JB.

(4) Install and tighten the screw that secures the lower instrument panel wire harness connector to the JB connector receptacle. Tighten the screw to 3.5 N·m (31 in. lbs.).

(5) Position the trim onto the right cowl side inner panel.

(6) Install and tighten the screw that secures the right cowl side inner trim panel and right front door sill trim to the door opening sill. Tighten the screw to 2.2 N·m (20 in. lbs.).

(7) Install and tighten the screw located above the fuse access opening that secures the trim panel to the right cowl side inner panel. Tighten the screw to 2.2 N·m (20 in. lbs.).

(8) Install the push nut that secures the right cowl side inner trim panel to the mounting stud on the JB.

(9) Install the fuse access panel by snapping it onto the right cowl side inner trim panel.

(10) Reconnect the battery negative cable.