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Relay And Fuse Block Removal/Installation: 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.
    Fig 1: Removing Relay And Fuse Block No. 1 From Relay And Fuse Block No. 3
    G08153526Courtesy of MAZDA MOTORS CORP.
  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.
    Fig 2: Removing Relay And Fuse Block No. 2 From Relay And Fuse Block No. 3
    G08153527Courtesy of MAZDA MOTORS CORP.
  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.
    Fig 3: Removing Terminal From Relay And Fuse Block
    G08153528Courtesy of MAZDA MOTORS CORP.
  4. For terminal relocation, line up the relays and fuse blocks of old and new parts and always verify each of the wiring harnesses in the wiring diagram.
    Fig 4: Identifying Relays And Fuse Blocks
    G08153529Courtesy of MAZDA MOTORS CORP.
    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.
    Fig 5: Identifying Relay And Fuse Block No. 2 And Relay And Fuse Block No. 3
    G08153530Courtesy of MAZDA MOTORS CORP.
  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.
    Fig 6: Identifying Relay And Fuse Block No. 1 And Relay And Fuse Block No. 3
    G08153531Courtesy of MAZDA MOTORS CORP.
  7. Install all the relays and fuses.
  8. Install bolt A.
    Fig 7: Bolt A With Torque Specifications
    G08153532Courtesy of MAZDA MOTORS CORP.
  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.
    Fig 8: Relay And Fuse Block Lower Cover Replacement Components With Torque Specifications
    G08153533Courtesy of MAZDA MOTORS CORP.
  11. Install bolt B.
  12. Install nut C and the wiring harness.
    Fig 9: Nut C And Wiring Harness With Torque Specifications
    G08153534Courtesy of MAZDA MOTORS CORP.
    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.
    Fig 10: Bolt D And Front Wiring Harness With Torque Specifications
    G08153535Courtesy of MAZDA MOTORS CORP.
  14. Install the following parts.
    1. Battery tray and PCM component. (See BATTERY REMOVAL/INSTALLATION [MZR 2.5] .)
    2. PCM connectors. (See BATTERY REMOVAL/INSTALLATION [MZR 2.5] .)
    3. PCM cover No. 1. (See BATTERY REMOVAL/INSTALLATION [MZR 2.5] .)
    4. Battery. (See BATTERY REMOVAL/INSTALLATION [MZR 2.5] .)
    5. Battery clamp. (See BATTERY REMOVAL/INSTALLATION [MZR 2.5] .)
    6. Battery box. (See BATTERY REMOVAL/INSTALLATION [MZR 2.5] .)
    7. Positive battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.5] .)
    8. Fresh-air duct (No. 3). (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5] .)
    9. Air cleaner case. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5] .)
    10. Air cleaner element. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5] .)
    11. Air hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5] .)
    12. Resonance chamber.(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5] .)
    13. Air cleaner cover. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5] .)
    14. MAF/IAT sensor connectors. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.5] .)
  15. After relay and fuse block replacement, perform verification. (See VERIFY RELAY AND FUSE BLOCK REPLACEMENT .)
  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.
    Fig 11: Securing Relay And Fuse Block Lower Cover And Front Wiring Harness Using Wiring Harness Tape
    G08153536Courtesy of MAZDA MOTORS CORP.
  18. Install front wiring harness securing clip G.
    Fig 12: Identifying Front Wiring Harness And Clip G
    G08153537Courtesy of MAZDA MOTORS CORP.
  19. Close the cover of the relay and fuse block lower cover in the direction of the arrow (8) shown in the figure.
    Fig 13: Identifying Relay And Fuse Block Lower Cover Closing Direction
    G08153538Courtesy of MAZDA MOTORS CORP.
  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.
    Fig 14: Identifying Relay And Fuse Block Cover Tilting Direction, Guide I, Tab H And Hook J
    G08153539Courtesy of MAZDA MOTORS CORP.
    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. (See BATTERY REMOVAL/INSTALLATION [MZR 2.5] .)
  23. Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.5] .)
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