Power Distribution Harness - Overlay Installation

The following service procedure will replace two portions of the power distribution harness.

Two individual sub-harnesses will be used two complete this procedure, they are:

1) Battery positive wiring branch. This sub-harness includes the battery positive cable and battery positive connections going to the power distribution box.

2) Cooling fan wire harness jumper. This sub-harness includes power and ground connections for the fan control harness and connections going to the power distribution box.

1. Remove one (1) battery pad (insulator) retaining strip, then remove the battery pad.

2. Remove the power distribution box retainer. Lift the power distribution box up and away from the wiring harness along the driver-side fender.

3. Turn the power distribution box over to access the bottom of the box, then cut the tie strap retaining the wiring harness to the power distribution box.





4. Remove the relays from the power distribution box. See Figure 6.





5. Remove the bottom cover from the power distribution box. See Figure 7.

6. Detach the pushpins and the tie strap retaining the battery positive cable to the battery support.





7. Cut the tape from the wiring harness under the power distribution box, then unzip the wiring harness wrap. See Figure 8. Expose 5-6 inches of the wiring.

8. Detach and remove the relay box from the power distribution box. See Figure 9.





9. Release the maxi fuse assembly retaining tabs, then slide the maxi fuses out from the bottom of the relay box. See Figure 9.

10. Disconnect all electrical connectors from the bottom of the power distribution box.





11. Mark and remove the Gray/Black wire from the 4-pin white connector. This connector was removed from the bottom of the power distribution box. See Figure 10.





12. Disconnect the battery positive busbar from the maxi fuses. Temporarily secure the three (3) eyelet wires back onto the maxi fuses. See Figure 11.

13. Remove the battery positive wiring branch from the bottom of the power distribution box.

14. Disassemble the battery positive cable. Also disconnect the starter motor electrical connector.

15. Remove the battery positive wiring branch from the vehicle.

16. Install the new battery positive wiring branch in the vehicle. Route the wiring through the bottom of the power distribution box.

17. Remove the wires from the maxi fuses, then connect the busbar and the wires to the maxi fuses. Tighten the retainers to securely.

18. Install the Gray/Black wire of the new battery cable into the marked terminal on the 4-pin white connector.





19. Mark and remove the relay connector spacers. See Figure 12.

20. Route the cooling fan wire harness jumper through the bottom of the power distribution box.





21. Connect the cooling fan wire harness jumper from the new overlay to the affected terminals in the relay box. See Figure 13. Follow color codes. Leave the original wires hanging at this time.





22. Using a Duraseal connector, splice the Purple/Black wire from the cooling fan wiring harness jumper to the Purple/Black wire removed from the relay box. See Figure 14.

23. Pull remaining wires of the old fan harness out of the power distribution box.

24. Install the relay connectors spacers. Make sure the correct spacer is used on the correct relay.

25. Install the maxi fuses into the relay box.

26. Install the relay box into the power distribution box.

27. Connect all electrical connectors to the bottom of the power distribution box.

28. Cut off the three wires, removed from the relay box. Cut the wire at the base of the exposed wiring harness so the wrap will cover them.

29. Zip the wiring harness wrap back to the bottom of the power distribution box, then secure the wrap with electrical tape.

30. Install the bottom cover to the power distribution box.

31. Disconnect two (2) fan control harness connectors.

32. Unclip wiring branch for two power distribution box to fan control harness connectors, then cut off the original harness near the headlamp opening.

33. Route and clip the new cooling fan wiring harness jumper.

34. Disconnect the air conditioning pressure switch electrical connector.





35. Remove the Purple wire from the air conditioning pressure switch connector. See Figure 15. Using supplied shrink tubing cover the terminal of the purple wire.





36. Insert the terminal from the cooling fan jumper branch into the air conditioning pressure switch electrical connector. See Figure 16.

37. Connect the air conditioning pressure switch electrical connector.

38. Route and secure the jumper branch to the main wiring harness loom.

39. Position the power distribution box in the installed position. Tighten the retainers securely.

40. Install the original relays into the power distribution box, then install the power distribution box cover.

41. Secure the battery positive cable to the battery support using tie strap and pushpins.

42. Assemble the battery positive cable. Also connect the starter motor electrical connector.

43. Install the battery pad.