Power Distribution Chrysler PT Cruiser I

DESCRIPTION

The power distribution system for this vehicle consists of the following components

1. Power Distribution Center (PDC)
2. Fuse Block

OPERATION

The power distribution system for this vehicle is designed to provide safe, reliable, centralized, and convenient to access, distribution of the electrical current required to operate all of the many standard and optional factory-installed electrical and electronic powertrain, chassis, safety, comfort and convenience systems. At the same time, these systems were designed to provide centralized locations for conducting diagnosis of faulty circuits, and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items.

These power distribution systems also incorporate various types of circuit control and protection features, including

1. Fuses
2. Fuse cartridges
3. Fusible links
4. Automatic resetting circuit breakers
5. Relays
6. Flashers
7. Timers
8. Circuit splice blocks.

Scheme 236

Scheme 237

Scheme 238

An instrument panel mounted cigar lighter/power outlet receptacle is optional equipment on this model. On models equipped with the optional Smoker's Package, the cigar lighter knob and heating element are included. On models without the Smoker's Package, the cigar lighter receptacle is equipped with a snap fit plastic cap and is treated as an auxiliary power outlet. The cigar lighter receptacle is installed in the instrument panel accessory switch bezel, which is located near the bottom of the instrument panel center stack area, below the radio. The cigar lighter base is secured by a snap fit within the center lower bezel. This power outlet has a constant 12 volt battery feed. (Scheme 236)

The cigar lighter receptacle is serviced with the accessory switch bezel and if defective, the entire switch bezel must be replaced. The plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if faulty or damaged, they must be replaced.

FRONT CONSOLE AND REAR CARGO MOUNTED

A front console mounted power outlet is standard equipment and a rear cargo area power outlet is optional equipment on this model. The front console mounted power outlet is mounted near the front of the console just in front of the cup holders. (Scheme 237) This outlet can be used as a cigar lighter or power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions. The rear power outlet is installed in the right rear quarter trim panel, near the spare tire jack. (Scheme 238) The power outlet base and mount are secured by a snap fit within the quarter trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. It has 12 volt battery voltage when the ignition is in the ON or ACC positions.

CIGAR LIGHTER/POWER OUTLET (INSTRUMENT PANEL AND CONSOLE MOUNTED)

The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current.

The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell.

Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat.

When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety.

POWER OUTLET (REAR CARGO AREA MOUNTED)

The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Power Distribution Center (PDC) through a fuse in the fuse block when the ignition is in the ON or ACC positions.

REMOVAL

This procedure applies to the Front Console and Rear Cargo Area mounted outlets on this vehicle. If the instrument panel mounted cigar lighter/power outlet is defective, the entire accessory switch bezel must be replaced.

Scheme 239

1. Disconnect and isolate the battery negative cable.
2. Look inside and note position of the retaining bosses. (Scheme 239) 1 - RETAINING BOSSES-ENGAGE PLIERS HERE 2 - PARTIALLY REMOVED 3 - EXTERNAL SNAP-RING PLIERS 4 - PULL BASE OUT-THROUGH MOUNTING RING
3. Using external snap ring pliers with 90 degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base.
4. Pull out the base through mounting ring by gently rocking pliers.
5. Disconnect the base wires.
6. Set base aside and remove base mount ring.

INSTALLATION

This procedure applies to the Front Console and Rear Cargo Area mounted outlets on this vehicle. If the instrument panel mounted cigar lighter/power outlet is defective, the entire accessory switch bezel must be replaced.

1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring.
2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location
3. Push base into the bezel till it locks.
4. Install cigar lighter cap.
5. Connect the battery negative cable.

Scheme 240

An electrical Fuse Block is located in the left front lower instrument panel. (Scheme 240) It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle.

The Fuse Block is positioned on a mounting bracket up and under the left instrument panel. It is secured by two screws. The fuse block is concealed behind a fuse panel cover. The fuse panel cover is a snap-fit access cover that conceals the fuse block fuses. A fuse layout placard is on the back of the end cap to ensure proper fuse identification.

The fuse block houses blade-type fuses and automatic resetting circuit breakers. Internal connection of all the fuse block circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to SYSTEM WIRING DIAGRAMS for complete circuit diagrams.

The fuses and circuit breakers are available for service replacement. The fuse block unit cannot be repaired and is only serviced as an assembly. If any circuit or the fuse block housing is faulty or damaged, the entire fuse block and instrument panel wire harness assembly must be replaced.

The Fuse Block is serviced with the instrument panel wire harness. If service is required to the fuse block, the entire instrument panel harness must be replaced.

1. Disconnect and isolate the battery negative cable.
2. Remove the instrument panel from the vehicle «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) .
3. With the instrument panel on the bench, de-trim the instrument panel enough to gain access to all screws and connectors to remove instrument panel wire harness with fuse block.

1. Install the new wire harness and fuse block.
2. Re-trim the instrument panel with what was necessary for harness removal.
3. Install instrument panel into vehicle «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) . Ensure that the wire terminals and connectors are in good condition and connectors are properly installed.
4. Connect the battery negative cable.

All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Power Distribution Center (PDC) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the PDC as part of the preparation procedures performed just prior to new vehicle delivery.

The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel.

The IOD fuse is disconnected from PDC fuse cavity 18 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. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device.

The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged.

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. Removing and installing the IOD fuse again with the ignition switch in the Off position will usually correct the scrambled radio display condition.

1. Turn the ignition switch to the Off position.
2. Remove the cover from the Power Distribution Center (PDC).
3. Remove fuse 18 from the PDC.

1. Insert fuse 18 into the Power Distribution Center (PDC).
2. Install the cover to the PDC.

Scheme 241

All of the electrical current distributed throughout this vehicle is directed through the standard equipment Power Distribution Center (PDC). (Scheme 241) The molded plastic PDC housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The PDC housing has a molded plastic cover. The PDC cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification.

The PDC housing is secured to the left inner fender well an indexing pin and one screw. All of the PDC outputs are through the integral engine compartment wire harness.

All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. The PDC houses up to ten six fuse cartridges, which replace all in-line fusible links. The PDC also houses up to twelve blade-type fuses, up to two full International Standards Organization (ISO) relays, and up to eight mini International Standards Organization (ISO) relays. Internal connection of all the PDC circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to SYSTEM WIRING DIAGRAMS for complete circuit diagrams.

The fusible link, fuses and relays are available for service replacement. The PDC unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the PDC is inoperative or damaged, the engine compartment wire harness assembly must be replaced.

The Power Distribution Center (PDC) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and engine compartment wire harness unit must be replaced. Refer to WIRING DIAGRAM INFORMATION for more information on the locations of the affected connectors.

1. Open hood.
2. Disconnect and isolate the battery negative cable.
3. Disconnect each of the engine compartment wire harness connectors.
4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components.
5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components.
6. Disengage and remove the PDC housing from its mounting bracket.
7. Remove the PDC and the engine compartment wire harness from the engine compartment as a unit.

The Power Distribution Center (PDC) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the PDC or the PDC housing is faulty or damaged, the entire PDC and engine compartment wire harness unit must be replaced.

Note. If the power distribution center (PDC) is being replaced with a new unit, be certain to transfer each of the fuses and relays from the old power distribution center to the proper cavities of the new power distribution center. Refer to WIRING DIAGRAM INFORMATION for the proper power distribution center cavity assignments.

1. Position the PDC in the engine compartment.
2. Align the PDC on its mounting bracket and install.
3. Route the engine compartment wire harness from the PDC through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to «WIRING DIAGRAM INFORMATION»(ref-248266) for more information on the harness routing and retainer locations.
4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to «WIRING DIAGRAM INFORMATION»(ref-248266) for more information on the ground eyelet locations.
5. Reconnect each of the engine compartment wire harness connectors. Refer to «WIRING DIAGRAM INFORMATION»(ref-248266) for more information on the locations of the affected connectors.
6. Torque nut retaining positive battery cable at PDC to 96 - 141 N.m (85 - 130 in. lbs.).
7. Reconnect the battery negative cable.
8. Close hood.
9. Verify vehicle and system operation.

1. Disconnect and isolate the battery negative cable.
2. Remove cover from Power Distribution Center (PDC).
3. Using special tool C-4817, grip the relay by the sides and pull upward with an even effort. (Scheme 242)

Scheme 242

1. Align relay with Power Distribution Center (PDC) and press into position.
2. Install cover to PDC.
3. Connect battery negative cable.

See also:
• (Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL)