Relay Box: Service and Repair
RELAY AND FUSE BLOCK REMOVAL/INSTALLATION
Removal
1. Remove the following parts.
a. Plug hole plate. Service and Repair
b. Battery cover. Removal and Replacement
c. Negative battery cable.
d. MAF/IAT sensor connectors. Service and Repair
e. Air cleaner cover. Service and Repair
f. Resonance chamber. Service and Repair
g. Air hose. Service and Repair
h. Air cleaner element. Service and Repair
i. Air cleaner case. Service and Repair
j. Fresh-air duct (No.3). Service and Repair
k. Positive battery cable. Removal and Replacement
l. Battery box. Removal and Replacement
m. Battery clamp. Removal and Replacement
n. Battery. Removal and Replacement
o. PCM cover No.1. Removal and Replacement
p. PCM connectors. Removal and Replacement
q. Battery tray and PCM component. Removal and Replacement
2. While pressing hook A in the direction of arrow (1) in the figure, remove the relay and fuse block cover in the direction of arrow (2).
CAUTION:
- Detaching tab B without detaching hook A could damage the relay and fuse block cover. When removing the relay and fuse block cover, always detach hook A first.
3. With tab C pressed in the direction of the arrow (3), disconnect the relay and fuse block connector in the direction of the arrow (5) while raising the lever in the direction of the arrow (4) as shown in the figure.
4. Remove all of the relays and fuses except for the EHPAS 80A fuse shown in the figure.
5. Remove ground terminal securing bolt A which branches from the front wiring harness, and clip D securing the front wiring harness.
6. Remove the relay and fuse block lower cover and the wiring harness tape securing the front wiring harness.
CAUTION:
- If a utility knife or nippers is used to remove the wiring harness tape, the blade tip could contact and sever the front wiring harness or damage the wiring cover. When using a utility knife or nippers to remove the wiring harness tape, be careful not to allow the blade tip to contact the front wiring harness.
7. Insert a flathead screwdriver or similar tool in the positions shown in the figure and pull the cover in the direction of the arrow (7) while moving it in the direction of the arrow (6), and open the cover.
8. Remove nut B and the wiring harness.
9. Using a flathead screwdriver or similar tool, lift up the relay and fuse block in the direction of the arrow (9) while pressing the hook E in the direction of the arrow (8) shown in the figure, and remove it.
10. Remove bolt C.
11. Remove the EHPAS 80A fuse.
12. Set the removed relay and fuse block aside so that it does not scratch the vehicle and parts.
13. Remove bolt D.
14. Remove tab F from the wheel apron panel (front), and remove the relay and fuse block lower cover in the direction of the arrow (10) shown in the figure.
Installation
CAUTION:
- If the terminal is installed incorrectly, it could damage electrical accessories and burn wiring harnesses. When relocating terminals after replacing the relay and fuse block, always reposition terminals one by one and perform the following procedures correctly so that the installation positions are correct.
NOTE:
- For easier access when performing terminal relocation, disassemble the relay and fuse block before removing the terminal.
1. Remove relay and fuse block No. 1 from relay and fuse block No.3 in the direction of the arrow (1) shown in the figure with tab A of relay and fuse block No.1 released.
2. Remove relay and fuse block No. 2 from relay and fuse block No.3 in the direction of the arrow (2) shown in the figure with tab B of relay and fuse block No.2 released.
3. Move the flathead screwdriver in the direction of the arrow (3) shown in the figure, release stopper C, pull the wiring harness in the direction of the arrow (4), and then remove the terminal from the relay and fuse block.
4. For terminal relocation, line up the relays and fuse blocks of old and news parts and always verify each of the wiring harnesses in the wiring diagram.
CAUTION:
- A terminal disconnection could cause electronic components and the system to not operate due to poor contact. After terminal relocation, lightly pull the wiring harnesses to verify that they cannot be pulled out.
NOTE:
- This procedure is performed for relay and fuse blocks No.1, 2, and 3.
5. Move relay and fuse block No.2 in the direction of the arrow (5) shown in the figure and install it to relay and fuse block No.3.
6. Move relay and fuse block No.1 in the direction of the arrow (6) shown in the figure and install it to relay and fuse block No.3.
7. Install all the relays and fuses.
8. Install bolt A.
9. Connect the relay and fuse block connector.
10. Insert tab F into the wheel apron panel (front) and install the relay and fuse block lower cover in the direction of the arrow (7) shown in the figure.
11. Install bolt B.
12. Install nut C and the wiring harness.
NOTE:
- For easier access after relay and fuse block replacement, do not assemble the relay and fuse block to the relay and fuse block lower cover.
13. Install securing bolt D with the ground wire branching from the front wiring harness.
14. Install the following parts.
a. Battery tray and PCM component. Removal and Replacement
b. PCM connectors. Removal and Replacement
c. PCM cover No.1. Removal and Replacement
d. Battery. Removal and Replacement
e. Battery clamp. Removal and Replacement
f. Battery box. Removal and Replacement
g. Positive battery cable. Removal and Replacement
h. Fresh-air duct (No.3). Service and Repair
i. Air cleaner case. Service and Repair
j. Air cleaner element. Service and Repair
k. Air hose. Service and Repair
l. Resonance chamber. Service and Repair
m. Air cleaner cover. Service and Repair
n. MAF/IAT sensor connectors. Service and Repair
15. After relay and fuse block replacement, perform verification.
16. Verify that there is no malfunction after relay and fuse block replacement, and assemble the relay and fuse block to the relay and fuse block lower cover.
17. Secure the relay and fuse block lower cover and front wiring harness using wiring harness tape.
18. Install front wiring harness securing clip G.
19. Close the cover of the relay and fuse block lower cover in the direction of the arrow (8) shown in the figure.
20. Tilt the relay and fuse block cover in the direction of the arrow (9) shown in the figure while hooking guide I to tab H to engage with hook J.
CAUTION:
- If tab H is installed after engaging hook J, the relay and fuse block cover could be damaged. Hook guide I to tab H before installing the relay and fuse block cover.
21. Connect the negative battery cable.
22. Install the battery cover. Removal and Replacement
23. Install the plug hole plate. Service and Repair
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.
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 Power Window System Initialization Procedure
- Clock
- Steering angle sensor initial point Programming and Relearning
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 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.
10. Perform a road test and verify that low speed, acceleration, shift-up, and shift-down conditions are normal.