Dodge Durango (DN). Manual — part 312

(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 stan-

chions 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(+) ter-
minal 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 con-

nector 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 Loca-
tions in the index of this service manual for the loca-
tion 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 Loca-
tions in the index of this service manual for the loca-
tion of more information on the headlamp and dash
wire harness connector locations.

(14) Reconnect the battery negative cable.

GENERATOR CARTRIDGE FUSE

If a generator cartridge fuse fails, be certain to

inspect and test the vehicle charging system before
replacing the cartridge fuse and returning the vehicle
to service. Refer to Charging System in the index of
this service manual for the charging system diagnos-
tic procedures.

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Unlatch and remove the cover from the Power

Distribution Center (PDC).

(3) Remove the two screws that secure the genera-

tor cartridge fuse to the two B(+) terminal stud bus
bars within the PDC.

(4) Remove the generator cartridge fuse from the

PDC.

INSTALLATION

(1) Position the generator cartridge fuse onto the

two B(+) terminal stud bus bars within the PDC.

(2) Install and tighten the two screws that secure

the generator cartridge fuse to the two B(+) terminal
stud bus bars within the PDC. Tighten the screws to
3.4 N·m (30 in. lbs.). Be certain that both screws
are tightened to the proper torque value.

(3) Install and latch the cover onto the PDC.
(4) Reconnect the battery negative cable.

JUNCTION BLOCK

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG 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 left outboard end of the instrument panel
(Fig. 8).

(3) Reach through the instrument panel fuse

access panel opening to access and remove the one
screw that secures the Junction Block (JB) to the left
instrument panel end bracket.

(4) Remove the steering column opening cover

from the instrument panel. Refer to Steering Col-
umn Opening Cover in the index of this service
manual for the location of the steering column open-
ing cover removal procedures.

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POWER DISTRIBUTION SYSTEMS

DN

REMOVAL AND INSTALLATION (Continued)

(5) Reach through the outboard side of the instru-

ment panel steering column opening to access and
disconnect all of the wire harness connectors from
the JB connector receptacles (Fig. 9).

(6) Reach through the outboard side of the instru-

ment panel steering column opening to access and
remove the relay and fuse block from the JB. Push
the relay and fuse block towards the left end of the
instrument panel to disengage its mounting slots
from the tabs on the JB.

(7) Reach through the outboard side of the instru-

ment panel steering column opening to access and
remove the one screw that secures the JB to the left
instrument panel end bracket.

(8) Reach through the outboard side of the instru-

ment panel steering column opening to remove the
JB from the left instrument panel end bracket.

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 man-
ual for the location of complete circuit diagrams
and cavity assignments for the JB.

(1) Reach through the outboard side of the instru-

ment panel steering column opening to position the
JB onto the left instrument panel end bracket.

(2) Reach through the outboard side of the instru-

ment panel steering column opening to install and
tighten the one screw that secures the JB to the left
instrument panel end bracket. Tighten the screw to
2.2 N·m (20 in. lbs.).

(3) Reach through the outboard side of the instru-

ment panel steering column opening to access and
install the relay and fuse block onto the JB by engag-
ing the relay and fuse block mounting slots with the
tabs on the JB.

(4) Reach through the outboard side of the instru-

ment panel steering column opening to access and
reconnect all of the wire harness connectors to the
JB connector receptacles.

(5) Install the steering column opening cover onto

the instrument panel. Refer to Steering Column
Opening Cover in the index of this service manual
for the location of the steering column opening cover
installation procedures.

(6) Reach through the instrument panel fuse

access panel opening to install and tighten the one
screw that secures the junction block to the left
instrument panel end bracket. Tighten the screw to
2.2 N·m (20 in. lbs.).

(7) Install the fuse access panel by snapping it

onto the left outboard end of the instrument panel.

(8) Reconnect the battery negative cable.

IGNITION-OFF DRAW FUSE

The Ignition-Off Draw (IOD) fuse is disconnected

from Junction Block (JB) fuse cavity 12 (Fig. 10)
when the vehicle is shipped from the assembly plant.
Dealer personnel must reconnect the IOD fuse when
the vehicle is being prepared for delivery in order to
restore full electrical system operation.

Fig. 8 Fuse Access Panel Remove/Install

1 – INSTRUMENT PANEL
2 – FUSE ACCESS PANEL
3 – SCREW

Fig. 9 Junction Block Remove/Install

1 – JUNCTION BLOCK
2 – INSTRUMENT PANEL
3 – SCREW
4 – CONNECTORS

DN

POWER DISTRIBUTION SYSTEMS

8O - 7

REMOVAL AND INSTALLATION (Continued)

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. Remov-
ing and installing the IOD fuse again with the igni-
tion switch in the Off position will usually correct
the scrambled radio display condition.

REMOVAL

(1) Turn the ignition switch to the Off position.
(2) Remove the fuse access panel by unsnapping it

from the left outboard end of the instrument panel.

(3) Grasp the upper and lower tabs of the IOD

fuse holder unit in fuse cavity 12 of the JB between
the thumb and forefinger and pull the unit firmly
outward.

(4) Install the fuse access panel by snapping it

onto the left outboard end of the instrument panel.

INSTALLATION

(1) Turn the ignition switch to the Off position.
(2) Remove the fuse access panel by unsnapping it

from the left outboard end of the instrument panel.

(3) To install the IOD fuse, use a thumb to press

the IOD fuse holder unit in fuse cavity 12 firmly into
the JB.

(4) Install the fuse access panel by snapping it

onto the left outboard end of the instrument panel.

RELAY AND FUSE BLOCK

The relay and fuse block is serviced as a unit with

the instrument panel wire harness. If any internal
circuit of the relay and fuse block or the relay and
fuse block housing is faulty or damaged, the entire
instrument

panel

wire

harness

unit

must

be

replaced.

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument panel assembly from

the dash panel. Refer to Instrument Panel Assem-
bly in the index of this service manual for the instru-
ment panel assembly removal procedures.

(3) Disconnect each of the instrument panel wire

harness connectors. Refer to Connector Locations
in the index of this service manual for the location of
more information on the instrument panel wire har-
ness connector locations.

(4) Remove all of the fasteners that secure each of

the instrument panel wire harness ground eyelets to
the instrument panel components. Refer to Connec-
tor Locations in the index of this service manual
for the location of more information on the ground
eyelet locations.

(5) Disengage each of the retainers that secure the

instrument panel wire harness to the instrument
panel components. Refer to Connector Locations in
the index of this service manual for the location of
more information on the instrument panel wire har-
ness retainer locations.

(6) Push the relay and fuse block towards the left

end of the instrument panel to disengage its mount-
ing slots from the tabs on the Junction Block (JB)
(Fig. 11).

(7) Remove the relay and fuse block and the

instrument panel wire harness from the instrument
panel as a unit.

Fig. 10 Ignition-Off Draw Fuse - Typical

1 – JUNCTION BLOCK
2 – IGNITION-OFF DRAW FUSE AND HOLDER
3 – LEFT INSTRUMENT PANEL END BRACKET

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POWER DISTRIBUTION SYSTEMS

DN

REMOVAL AND INSTALLATION (Continued)

INSTALLATION

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

(1) Position the relay and fuse block and the

instrument panel wire harness onto the instrument
panel.

(2) Install the relay and fuse block by engaging its

mounting slots onto the tabs on the Junction Block
(JB).

(3) Engage each of the retainers that secure the

instrument panel wire harness to the instrument
panel components. Refer to Connector Locations in
the index of this service manual for the location of
more information on the instrument panel wire har-
ness retainer locations.

(4) Install all of the fasteners that secure each of

the instrument panel wire harness ground eyelets to
the instrument panel components. Refer to Connec-
tor Locations in the index of this service manual
for the location of more information on the ground
eyelet locations.

(5) Reconnect each of the instrument panel wire

harness connectors. Refer to Connector Locations
in the index of this service manual for the location of
more information on the instrument panel wire har-
ness connector locations.

(6) Install the instrument panel assembly onto the

dash panel. Refer to Instrument Panel Assembly
in the index of this service manual for the location of
the instrument panel assembly installation proce-
dures.

(7) Reconnect the battery negative cable.

Fig. 11 Relay and Fuse Block Remove/Install

1 – JUNCTION BLOCK
2 – RELAY AND FUSE BLOCK

DN

POWER DISTRIBUTION SYSTEMS

8O - 9

REMOVAL AND INSTALLATION (Continued)