RELAY AND FUSE BLOCK REMOVAL/INSTALLATION

id092100498600

Replacement Part

Band
 
Quantity: 2
 
Location of use: Relay and fuse block lower cover

Note
•  When replacing the relay and fuse block, it is necessary to switch terminals from the relay and fuse block terminal prior to replacement to the relay and fuse block terminal on the replacement. When switching terminals, ready the replacement relay and fuse block before pulling out the terminal of the relay and fuse block prior to replacement. This is because it is necessary to switch the terminals one at a time so that the installation positions are not mistaken.

Removal

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

2.  Remove the air cleaner case. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].) (See AIR CLEANER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

3.  Remove the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 1.8].) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

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.  Disconnect the wiring harness connectors.

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8.  Remove the nuts.

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

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10.  While pressing the clip tabs of front wiring harness protector in the direction of the arrows (1) shown in the figure, pull the clip of front wiring harness protector in the direction of the arrow (2) shown in the figure to detach the clip tabs of front wiring harness protector from the body.

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11.  Pull out the front wiring harness protector clip.

12.  Lift up the front wiring harness protector caps in the direction of the arrow shown in the figure.

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13.  Pull out the front wiring harness protector from the stud bolt and set it aside as shown in the figure.

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14.  Cut the bands shown in the figure.

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

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17.  Detach all of the relay and fuse block middle cover and the relay and fuse block lower cover.

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

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19.  Pull out the wiring harness clip.

20.  Remove the relay and fuse block lower cover.

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

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22.  Remove the wiring harness connectors.

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23.  Remove the relay and fuse block middle cover in the direction of the arrow shown in the figure.

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24.  Remove the bolt.

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25.  Remove the power supply cable.

26.  Disconnect the wiring harness connectors.

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27.  Detach all the relay and fuse block tabs from the relay and fuse block middle cover, and remove the relay and fuse block middle cover.

28.  Set the removed relay and fuse block aside so that it does not scratch the vehicle and parts.


Installation

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

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2.  Relocate all relay and fuse terminals to the new relay and fuse block.

Caution
•  If terminals are installed incorrectly, it could damage electrical accessories and burn wiring harnesses. When relocating terminals after replacing the relay and fuse block, line up the relay and fuse blocks of old and news parts and always verify each of the wiring harnesses in the wiring diagram so that the installation positions are correct.
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•  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.

3.  Connect the wiring harness connectors.

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4.  Install the bolt shown in the figure and install the power supply cable.

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5.  Insert the relay and fuse block middle cover into the relay and fuse block.

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6.  Insert all the relay and fuse block tabs into the relay and fuse block middle cover and install the relay and fuse block middle cover.

7.  Insert the wiring harness connectors into the relay and fuse block middle cover.

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8.  Install all the wiring harness connectors to the relay and fuse block middle cover.

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9.  Insert all the relay and fuse block middle cover tabs into the relay and fuse block lower cover and install the relay and fuse block lower cover.

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10.  Install the wiring harness clip to the relay and fuse block lower cover.

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11.  Install the band shown in the figure.

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12.  Insert the front wiring harness protector into the stud bolts.

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13.  Insert the front wiring harness protector cap into the stud bolt.

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14.  Install the front wiring harness protector clip tabs to the body.

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15.  Insert the relay and fuse block into the stud bolts.

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16.  Install nut A.

17.  Install nut B.

18.  Install nut C.

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19.  Connect the wiring harness connectors.

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20.  Install the relay and fuse block upper cover.

21.  Install the parts removed in Steps 2 and 3 in “REMOVAL”. (See Removal.)

22.  Perform the "Verify Relay and Fuse Block Replacement". (See Verify relay and fuse block replacement.)

23.  Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)


Verify relay and fuse block replacement

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

2.  Switch the ignition ON (engine off).

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

4.  Inspect for DTCs. (See DTC INSPECTION.)

•  If a DTC is displayed, repair the malfunctioning location according to the applicable DTC troubleshooting.
―  After completion of repairs, clear all DTCs stored in the module. (See CLEARING DTC.)

5.  If there is no malfunction in Step 1, 3, and 4, start the engine and maintain the idle status.

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

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

8.  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)

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