Service Procedure With an Alternator Circuit Fuse

Service Procedure for Grand Cherokee (ZJ) Vehicles Equipped With an Alternator Circuit Fuse and ALL Cherokee (XJ) Vehicles

1. With the ignition key in the OFF position, disconnect the battery.

Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.





2. Remove and discard the power distribution center (PDC) alternator fuse cover (Figure 1).

3. Remove the two nuts which retain the battery and alternator cables to the PDC (Figure 1). Remove and discard the PDC alternator fuse (Mega Fuse). Save the nuts for reuse.

NOTE:
For Grand Cherokee (ZJ) vehicles, if no alternator circuit fuse is present and the battery cable and alternator cable are both connected to the same PDC stud, follow the service procedure for "Grand Cherokee (ZJ) Vehicles Without an Alternator Circuit Fuse".

4. Inspect the PDC studs and the surrounding areas for any signs of damage.

5. ^ If the front stud for the alternator terminal is damaged, remove the stud from the adapter plate by prying it out with a screwdriver. Install the provided stud.

^ If the adapter plate is damaged, replace it as follows:

A. Remove the PDC from its mounting bracket.





B. Remove the PDC bottom cover (Figure 2).

C. Unsnap the adapter plate from the PDC. Discard the adapter plate.

D. Install the provided stud in the provided adapter plate.

E. Snap the adapter plate on to the PDC.

F. Install the PDC bottom cover.

G. Install the PDC into the mounting bracket.

^ If the rear stud for the battery terminal is damaged, clean the threads by using a thread chaser.

6. Install the alternator and battery cable terminals over the appropriate stud.

7. Install the provided fuse link over the two studs.





8. Hand start the nut on the battery cable (rear) stud. Position the fuse link terminal so that it is perpendicular (900) to the stud side of the PDC case (Figure 3). Tighten the nut to 75 in-lb (8.5 Nm). Repeat for the alternator cable (front) stud.

IMPORTANT:
Do NOT over tighten. You may damage the PDC or adapter plate. Do not use an automatic rachet or screwdriver. Extra care must be taken with the alternator stud to prevent adapter plate damage.





9. Position the wire portion of the fuse link so that it forms an upside-down "U" shape between both studs (Figure 4).

10. Install the two (2) provided caps over the studs and nuts.

11. Reconnect the battery.