Toyota
Dodge Durango
 Service Manual
Power Distribution System » Removal and installation
Power distribution center

The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness.

If any internal circuit of the PDC or the PDC housing is 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 cover from the PDC.

(6) Disconnect the engine wire harness in-line connector from the PDC connector receptacle (Fig. 5).

Fig. 5 Engine Wire Harness In-Line Connector Fig. 5 Engine Wire Harness In-Line Connector

1 - COVER

2 - POWER DISTRIBUTION CENTER

3 - ENGINE WIRE HARNESS IN-LINE CONNECTOR

4 - CLIP

(7) Slide the engine wire harness retainer clip upward and disengage the harness from the trough on the rear of the PDC housing.

(8) Remove the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC and remove the eyelet from the stud (Fig. 6).

(9) Remove the nut that secures the eyelet of the battery positive cable PDC take out to the forward B(+) terminal stud in the PDC and remove the eyelet from the stud.

(10) Remove the screw that secures the PDC housing to the left front fender wheel housing (Fig. 7).

(11) Disengage the latches for the two PDC mounts and lift the unit off of the battery tray stanchions.

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

INSTALLATION

NOTE: If the PDC is being replaced with a new unit, be certain to transfer each of the blade-type fuses, cartridge 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.

Fig. 6 Battery and Generator Connections to PDC Fig. 6 Battery and Generator Connections to PDC

1 - POWER DISTRIBUTION CENTER

2 - COVER

3 - NUT

4 - BATTERY POSITIVE CABLE PDC TAKE OUT

5 - BATTERY NEGATIVE CABLE GENERATOR OUTPUT TAKE OUT

6 - NUT

Fig. 7 Power Distribution Center Remove/Install Fig. 7 Power Distribution Center Remove/Install

1 - POWER DISTRIBUTION CENTER

2 - BATTERY TRAY

3 - LEFT FRONT FENDER WHEEL HOUSING

4 - SCREW

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

(2) Install the two PDC mounts onto the two stanchions of the battery tray.

(3) Install and tighten the screw that secures the PDC housing to the left front fender wheel housing.

Tighten the screw to 7.9 N*m (70 in. lbs.).

(4) Install the eyelet of the battery positive cable PDC take out onto the forward B(+) terminal stud in the PDC.

(5) Install and tighten the nut that secures the eyelet of the battery positive cable PDC take out to the forward B(+) terminal stud in the PDC. Tighten the nut to 9 N*m (80 in. lbs.).

(6) Install the eyelet of the battery negative cable generator output take out onto the rearward B(+) terminal stud in the PDC.

(7) Install and tighten the nut that secures the eyelet of the battery negative cable generator output take out to the rearward B(+) terminal stud in the PDC. Tighten the nut to 9 N*m (80 in. lbs.).

(8) Engage the engine wire harness in the trough on the back of the PDC housing and secure it with the retainer clip.

(9) Reconnect the engine wire harness in-line connector to the PDC in-line connector receptacle.

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

(11) 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.

(12) 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.

(13) 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.

(14) Reconnect the battery negative cable.

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