RELAY AND FUSE BLOCK REMOVAL/INSTALLATION

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1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT i-stop)].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].)

2.  Remove the air cleaner assembly. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  While pressing the relay and fuse block upper cover hook in the direction of the arrow (1) shown in the figure, lift up the relay and fuse block upper cover in the direction of the arrow (2) to detach the relay and fuse block upper cover hook from the relay and fuse block middle cover tab.

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5.  Remove the relay and fuse block upper cover.

6.  Remove all the relays and fuses.

Caution

•  If the relay and fuse block is removed with the relays and fuses installed, the area around the relay and fuse block may contact the relays or fuses and damage the them. Before removing the relay and fuse block, remove all the relays and fuses.

7.  Remove the front body control module (FBCM). (See FRONT BODY CONTROL MODULE (FBCM) REMOVAL/INSTALLATION.)

8.  While pressing the relay and fuse block hook in the direction of the arrow (1) shown in the figure, set the emission wiring harness away from the relay and fuse block hook.

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9.  Disconnect the emission wiring harness connectors.

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10.  Remove the nut and bolt.

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11.  Insert a tape-wrapped flathead screwdriver into the service hole in the position shown in the figure.

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12.  While pressing the clip tab of the relay and fuse block in the direction of the arrow (1) shown in the figure, pull the clip in the direction of the arrow (2) to detach the clip tab from the engine mount.

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13.  Pull out the relay and fuse block from the stud bolt and set it aside as shown in the figure.

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14.  While pressing the clip tabs of front wiring harness protector No.2 in the direction of the arrows (1) shown in the figure, pull the clip in the direction of the arrow (2) shown in the figure to detach the clip tabs from the engine mount.

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15.  Remove the front wiring harness protector No.2 clip.

16.  Lift up the front wiring harness protector No.2 cap in the direction of the arrow (1) shown in the figure.

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17.  Pull out front wiring harness protector No.2 from the stud bolt and set it aside as shown in the figure.

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18.  Cut the band shown in the figure.

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19.  Insert a flathead screwdriver into the gap between the relay and fuse block middle cover tabs and the relay and fuse block lower cover as shown in the figure.

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20.  Move the flathead screwdriver in the direction of the arrow (1) shown in the figure, pull down the relay and fuse block lower cover in the direction of the arrow (2) shown in the figure, and detach the relay and fuse block middle cover tabs from the relay and fuse block lower cover.

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21.  Detach all the relay and fuse block middle cover tabs from the relay and fuse block lower cover, and remove the relay and fuse block lower cover from the relay and fuse block middle cover. (See Relay and Fuse Block Lower Cover Installation Note.)

22.  While pressing the wiring harness clip tabs in the direction of the arrows (1) shown in the figure, push out the clip in the direction of the arrow (2) shown in the figure to detach the clip tabs from the relay and fuse block.

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23.  Insert a flathead screwdriver into the service hole in the position shown in the figure.

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24.  Move the flathead screwdriver in the direction of the arrow (1) shown in the figure, lift up the front wiring harness connectors in the direction of the arrow (2) shown in the figure, and detach the connector tabs from the relay and fuse block middle cover.

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25.  Move the front wiring harness connector in the direction of the arrow (1) shown in the figure, release the hook, and pull it out from the relay and fuse block middle cover.

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26.  Insert the flathead screwdriver into the gap between the relay and fuse block middle cover and the relay and fuse block shown in the figure.

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27.  Move the flathead screwdriver in the direction of the arrow (1) shown in the figure, pull up the relay and fuse block middle cover in the direction of the arrow (2) shown in the figure, and detach the relay and fuse block tabs from the relay and fuse block middle cover.

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28.  Remove the bolt.

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29.  Remove the ground.

30.  Move the flathead screwdriver in the direction of the arrow (1) shown in the figure, pull the wiring harness in the direction of the arrow (2) while pressing the stopper, and detach the relay or fuse terminal from the stopper.

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31.  Remove the relay or fuse terminal.

Caution

•  A terminal disconnection could cause electronic components and the system to not operate normally due to poor contact. After terminal relocation, lightly pull the wiring harnesses to verify that they cannot be pulled out.

Note

•  For terminal relocation, line up the relays and fuse blocks of the old and news parts and always verify each of the wiring harnesses in the wiring diagram.

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32.  Install in the reverse order of removal.

33.  Perform verify relay and fuse block replacement. (See Verify Relay and Fuse Block Replacement.)

Relay and Fuse Block Lower Cover Installation Note

Note

•  When installing the relay and fuse block lower cover to the relay and fuse block middle cover, the wiring harness could get caught between the relay and fuse block middle cover and the relay and fuse block lower cover resulting in open or short circuit in the wiring harness. When installing the relay and fuse block lower cover, disassemble the relay and fuse block lower cover and install one at a time.

1.  Insert a flathead screwdriver into the gap between relay and fuse block lower covers No.1 and 2 shown in the figure.

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2.  Move the flathead screwdriver in the direction of the arrow (1) shown in the figure, pull up relay and fuse block lower cover No.1 in the direction of the arrow (2) shown in the figure, and detach the relay and fuse block lower cover No.1 tab from relay and fuse block lower cover No.2.

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3.  Detach all the relay and fuse block lower cover No.1 tabs from relay and fuse block lower cover No.2, and remove relay and fuse block lower cover No.1 from relay and fuse block lower cover No.2.

4.  Install relay and fuse block lower covers No.1 and 2.

Verify Relay and Fuse Block Replacement

1.  Temporarily connect the negative battery cable to verify that the related wiring harness is not heated.

2.  Switch the ignition ON (engine off).

3.  Verify that the fuse is not burnt out and the related wiring harness is not heated.

4.  Perform the initial settings for the following systems:

―  Power window system (See POWER WINDOW SYSTEM INITIALIZATION PROCEDURE.)

―  Clock and audio

―  i-stop system (With i-stop system) (See BATTERY CONDITION INITIALIZATION SETTING (i-stop SETTING) [SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See BATTERY CONDITION INITIALIZATION SETTING (i-stop SETTING) [SKYACTIV-D 2.2].)

―  Tire pressure monitoring system (TPMS) (See TIRE PRESSURE MONITORING SYSTEM INITIALIZATION PROCEDURE.)

―  Sunroof system (See SUNROOF SYSTEM INITIALIZATION PROCEDURE.)

5.  Verify DTCs using the M-MDS.

•  If a DTC is displayed, repair the malfunctioning part according to the corresponding DTC inspection.

―  After completion of repairs, clear all DTCs stored in the module.

6.  If there is no malfunction in Step 1, 3, and 5, start the engine and maintain the idle status.

7.  Operate all the switches of the interior/exterior lights of the vehicle and verify that all the light bulbs illuminate and flash.

8.  Operate the audio, climate control, wiper switch, and selector lever (ATX) and verify that they operate correctly.

9.  Shift the selector lever to the P position, race the engine at approx. 3,000 rpm from engine idling, and verify that there is no malfunction. (ATX)

10.  Perform a road test and verify that low speed, acceleration, shift-up, and shift-down conditions are normal. (ATX)