Toyota
Jeep Cherokee
 Service Manual
Power distribution systems » 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
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
Fig. 5 Power Distribution Center Remove/Install

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

Fig. 6 PDC Mounting Bracket Remove/Install
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.

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