RELAY AND FUSE BLOCK REMOVAL/INSTALLATION

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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.)

2.  Remove the following parts:

(1)  Air cleaner, air hose and fresh air duct as a single unit (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

(2)  Service plug (with i-ELOOP) (See SERVICE PLUG DISCONNECTION/CONNECTION [i-ELOOP].)

(3)  Terminal cover (with i-ELOOP) (See BATTERY REMOVAL/INSTALLATION.)

(4)  DC-DC converter (i-ELOOP) (with i-ELOOP) (See DC-DC CONVERTER (i-ELOOP) REMOVAL/INSTALLATION [i-ELOOP].)

3.  Remove the battery. (See BATTERY REMOVAL/INSTALLATION.)

Caution

•  When removing the relay and fuse block upper cover, it may contact the body and become scratched and damaged. Carefully remove the relay and fuse block upper cover.

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.

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.

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

7.  Remove the wiring harness from the relay and fuse block hook.

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8.  Disconnect the connectors.

9.  Remove the nut.

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10.  Remove the bolt.

11.  Pull out the relay and fuse block from the stud bolt.

12.  Pull out the pin of the relay and fuse block from the body.

13.  Cut the bands.

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14.  While pressing the tab of the relay and fuse block middle cover in the direction of arrow (1) shown in the figure using a tape-wrapped flathead screwdriver, pull the relay and fuse block middle cover and relay and fuse block lower cover in the direction of arrows (2) to detach the tab of the relay and fuse block middle cover from the relay and fuse block lower cover.

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15.  Detach all tabs of the relay and fuse block middle cover from the relay and fuse block lower cover and remove the relay and fuse block lower cover.

16.  While pressing the tabs of the clip in the direction of arrows (1) shown in the figure, push the clip in the direction of arrow (2) to remove the clip from the relay and fuse block lower cover.

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17.  Remove the connectors from the relay and fuse block according to the following procedure.

(1)  While pressing the tab of the relay and fuse block in the direction of arrow (1) shown in the figure using a tape-wrapped flathead screwdriver, pull the connector in the direction of arrow (2) to disconnect the connector from the relay and fuse block.

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18.  While pressing the tab of the relay and fuse block in the direction of arrow (1) shown in the figure using a tape-wrapped flathead screwdriver, pull the relay and fuse block middle cover in the direction of arrow (2) to detach the tab of the relay and fuse block from the relay and fuse block middle cover.

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19.  Detach all tabs of the relay and fuse block from the relay and fuse block middle cover and remove the relay and fuse block middle cover.

20.  Remove the bolt.

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21.  Remove the wiring harness.

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

Installation

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 relocate the terminals one by one so that the installation positions are correct while verifying the wiring diagram.

•  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.

•  Installing a fuse with the incorrect fuse capacity could damage electronic components and burn wiring harnesses. When relocating the fuses during relay and fuse block replacement, perform the procedures while verifying the wiring diagram so that the installation positions and fuse capacities are correct.

1.  While pressing the stopper using a tape-wrapped flathead screwdriver in the direction of the arrow (1) shown in the figure, pull the wiring harness in the direction of the arrow (2) shown in the figure to detach the fuse terminal from the stopper.

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

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3.  Install the wiring harness.

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4.  Install the bolt.

5.  Install the relay and fuse block middle cover to the relay and fuse block.

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6.  Install the connectors to the relay and fuse block.

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7.  Install the clip.

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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.

8.  While pressing the tab of relay and fuse block lower cover No.1 in the direction of arrow (1) shown in the figure using a tape-wrapped flathead screwdriver, pull relay and fuse block lower cover No.2 in the direction of arrow (2) to detach the tab of relay and fuse block lower cover No.1 from relay and fuse block lower cover No.2.

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9.  Detach all tabs of relay and fuse block lower cover No.1 from relay and fuse block lower cover No.2 and disassemble the relay and fuse block lower cover.

Caution

•  If the wiring harness gets caught between the relay and fuse block middle cover and the relay and fuse block lower cover, an open or short circuit may occur. When installing the relay and fuse block lower cover, install it while verifying that the wiring harness does not get caught.

10.  Install the relay and fuse block lower cover No.1 and No.2 to the relay and fuse block middle cover.

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11.  Install the bands.

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Caution

•  If the wiring harness contacts the edge of the body, an open or short circuit may occur. When installing the relay and fuse block, install it while verifying that the wiring harness does not contact the edge of the body.

12.  Insert the pin of the relay and fuse block into the body.

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13.  Insert the relay and fuse block into the stud bolt.

14.  Install the bolt.

15.  Install the nut.

16.  Connect the connectors.

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17.  Install the wiring harness to the relay and fuse block hook.

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

19.  Install all the relays and fuses.

20.  Install the relay and fuse block upper cover.

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21.  Install the battery. (See BATTERY REMOVAL/INSTALLATION.)

22.  Install the following parts:

(1)  DC-DC converter (i-ELOOP) (with i-ELOOP) (See DC-DC CONVERTER (i-ELOOP) REMOVAL/INSTALLATION [i-ELOOP].)

(2)  Terminal cover (with i-ELOOP) (See BATTERY REMOVAL/INSTALLATION.)

(3)  Service plug (with i-ELOOP) (See SERVICE PLUG DISCONNECTION/CONNECTION [i-ELOOP].)

(4)  Air cleaner, air hose and fresh air duct as a single unit (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

23.  Perform the "Verify relay and fuse block replacement". (See Verify relay and fuse block replacement.)

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.  Perform the initial settings for the following systems:

?  i-stop control (with i-stop system) (See BATTERY CONDITION INITIALIZATION SETTING (i-stop SETTING).)

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

?  Clock and audio

?  Tire pressure monitoring system (TPMS) (See TIRE PRESSURE MONITORING SYSTEM INITIALIZATION PROCEDURE [INDIRECT TIRE PRESSURE MONITORING SYSTEM (TPMS) (WITH TPMS SET SWITCH)].)

?  Sunroof system (with 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.  Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

7.  Start the engine and maintain the idle status.

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

9.  Operate the audio, climate control, wiper and washer switch, and selector lever and verify that they operate correctly.

10.  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.

11.  Perform a road test and verify that low speed, acceleration, shift-up/shift-down conditions are normal.