PDU Wiring Harness Replacement.
J1 Wiring Harness Replacement. (See figures 4-9 and 4-10).
Release cover latch and open PDU cover.
Detach J1 wiring harness wires from terminal board TB1 (1, figure 4-10) and ground
stud E1 (2).
Remove two screws (3) and two washers (4) and remove K1 contactor cover (5) from
terminals A2, B2 and C2. Detach one J1 wire from each of these terminals.
Remove all tiedown straps binding J1 harness wires to J6 harness wires.
Remove three nuts (6) and open three clamps (7) Remove two J1 wires.
Remove four screws (8), four flat washers (9) and four nuts (10) and pull J1 wiring
harness out of PDU housing (11). Remove gasket (12).
Unscrew and remove connector cover (13) from connector J1 (14).
Slide gasket (12) over harness wires and up against flange of connector (14).
Feed wires through J1 opening in PDU housing (11).
Seat flange of connector J1 (14) against housing (11) and fasten with four screws (8),
four flat washers (9) and four nuts (10). Make sure tab of connector cover chain (14) is
mounted to flange with lower right corner hardware.
Install connector cover (13) on connector J1 (14).
Using figure 4-9 for wire routing information, connect two 16 gauge wires to terminal
board TB1 (1), two 12 gauge wires and one 6 gauge wire to ground stud E1 (2) and
three 1 gauge wires to contactor K1 (15). Install K1 cover (5) using two screws (3) and
two washers (4).
Route two 16 gauge wires (to TB1) through clamps (7) and install nuts (6). Bind 16
gauge wires to J6 harness wires with tiedown straps.
Close and secure PDU cover.