Power Distribution Harness - Installation

1. Transfer the following components:

- Transfer relays and fuses from old power distribution box to the new power distribution box. If equipped with Daytime Running Lights, remove shorting bar from relay location before installing relay.

- Transfer the blue speed control cut-out relay, if equipped.

2. Modify brake ON/OFF switch wiring as follows:





- Shorten the brake on/off switch wiring from 28 inches to 13 inches by bundling the wiring together. Use electrical tape to secure the bundle. Make sure the bundle is 1 1/2 inches from the brake on/off switch connector. See Figure 17.

3. With an assistant's help, route the wiring harness into the passenger compartment. Make sure the grommet is completely seated in the bulkhead.

4. On 1996-1997 models, install driver-side rocker panel ground wire as follows:

- Install ground wire retainer to rocker panel. Tighten retainer securely.

- Position carpet and padding in installed position.

- Position kick panel/rocker trim panel in installed position.

- Install kick panel/rocker trim panel retainers.

- Seat weather strip back in door jamb.

5. Connect the rear lamp connector.

6. Attach the following connectors to the fuse box bracket:

- Blue speed control cut-out relay, if equipped.

- Rear lamp connector.

- Dead plug, if equipped.

7. Install the fuse box bracket.

8. Install the five (5) female connectors into the back of the organizer.

9. Slide the organizer onto the fuse box bracket.

10. Connect the five (5) male connectors to the correct female connectors.

11. On 1996-1997 models, attach diagnostic link connector into its holder.

12. Position the fuse box close to the installed position, then connect the seven (7) connectors to the fuse box.

13. Install the fuse box to the fuse box bracket.





14. Connect the brake on/off switch connector. Tie-strap the bundle to the brake pedal support bracket. See Figure 18.

15. Install the knee bolster.

16. On Mystique models, install the knee bolster storage compartment.

17. Loosely route the power distribution harness around the engine compartment as follows:

- Route the wiper motor wiring into the cowl area. Make sure the grommet is completely seated in the cowl.

- Route the wiring harness half-way down the driver-side fender.

- Route the wiring to the hydraulic control unit. Secure the wiring with two (2) pushpins.

- Route the wiring to the driver-side front antilock brake wheel sensor.

- Route the wiring harness down the rest of the driver-side fender.

- Route the wiring harness left elbow casing to the driver-side of the tie bar. Secure the elbow pushpins.

- Route the wiring harness across the tie bar.

- Route the wiring harness right elbow casing to the passenger-side of the tie bar. Secure the elbow with pushpins.

- Position the driver-side side air deflector into the installed position and secure with a pushpin.

- Swing down the four (4) clips securing the wiring harness to the tie bar.

- Position the passenger-side side air deflector into the installed position and secure with a pushpin.

18. Install and connect the wiper motor and transmission assembly. Tighten the retainers to 8 Nm (71 lb-in). Secure the wiring to the transmission with a single tie strap.

19. Position the speed control servo mounting bracket.

20. Connect then attach the hood lamp connector.

21. On 1995 models, connect the two (2) diagnostic link connector connectors to the cap.

22. On 1995 models, connect the antilock brake diagnostic connector to the left strut tower.

23. Install and connect the speed control servo. Tighten the retainer to 57 Nm (44-62 lb-in). Remove shorting bar from hardshell before connection.

24. Install the leaf screen and both wiper arms. Tighten the wiper arm retainers to 25 Nm (18 lb/ft).

25. Connect the hydraulic control unit and the brake fluid level sensor connector.

26. Slide the 42-pin connector onto its mounting bracket.

27. Position the power distribution box close to the installed position.

28. Route the positive battery cable under the battery support. Attach pushpins and install tie strap.

29. Install the negative cable ground wire. Tighten the retainer securely.

30. Final install the power distribution box. Tighten the retainer to 8-12 Nm (6-8 lb-ft).

31. Install the battery pad and the retaining strip.

32. Assemble the positive and negative battery cables. Connect the starter connector.

33. Route the driver-side marker lamp and horn/fog lamp wiring. Secure the wiring harness with pushpins.

34. Connect and install the driver-side marker lamp.

35. Connect the driver-side headlamp connectors and the driver-side front primary airbag crash sensor connector.

NOTE:
This grounding location could have 1 or 2 eyelets, depending on vehicle options.

36. Install ground wire(s). Tighten retainer securely.

37. Route the passenger-side marker lamp wiring. Secure the wiring with a pushpin.

38. Connect and install the passenger-side marker lamp.

39. Route the passenger-side horn/fog lamp wiring. Attach the protective clip onto the inner fender.

40. Connect the passenger-side headlamp connectors and the passenger-side front primary airbag crash sensor connector.

41. Connect the hood switch connector, then attach the connector pushpin.

42. Connect the traction control motor connectors, then attach the connector pushpin.

43. Connect the air conditioning pressure cutoff switch connector.

44. Route the final part of the wiring harness up the passenger-side fender. Secure the wiring harness with pushpins.

45. Position the degas bottle close to the installed position, then connect the low coolant sensor connector. Remove shorting bar from hardshell before connection.

46. Install the degas bottle.

47. Route the passenger-side antilock brake front wheel sensor wiring harness down through the fender grommet.

48. On vehicles equipped with antilock brakes, connect connector C124, then attach the connector pushpin.

49. On 1995 models, connect the evaporative emissions purge connector, then attach the connector pushpin.

50. On 1996-1997 models, attach then connect the vapor management valve connector.

51. Raise and support the vehicle.

52. Install the speed control servo bracket mounting nuts.

53. Connect the driver-side antilock brake front wheel sensor connector, then secure the wiring with pushpins.

54. On vehicles equipped with a 2.0L engine, install the fender well air intake resonator.

55. Connect the driver-side horn/fog lamp connectors, then secure the wiring with pushpins.

56. Position the air conditioning accumulator assembly in installed position. Tighten the retainer to 6-8 Nm (4-6 lb-ft).

57. Connect the passenger-side horn/fog lamp connectors, then secure the wiring with pushpins.

58. Install, unplug and connect the windshield washer bottle.

59. Connect the passenger-side antilock brake front wheel sensor connector, then secure the wiring with pushpins.

60. Install both inner fender well splash shields.