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Relay And Fuse Block Removal/Installation: 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.
    Fig 1: Pressing Stopper Using Tape-Wrapped Flathead Screwdriver
    G10950755Courtesy of MAZDA MOTORS CORP.
  2. Relocate all relay and fuse terminals to the new relay and fuse block.
    Fig 2: Identifying Relay And Fuse Block
    G10950756Courtesy of MAZDA MOTORS CORP.
  3. Install the wiring harness.
    Fig 3: Identifying Relay And Fuse Block, Wiring Harness Or Bolt With Torque Specification
    G10950757Courtesy of MAZDA MOTORS CORP.
  4. Install the bolt.
  5. Install the relay and fuse block middle cover to the relay and fuse block.
    Fig 4: Identifying Relay And Fuse Block With Middle Cover And Tabs
    G10950758Courtesy of MAZDA MOTORS CORP.
  6. Install the connectors to the relay and fuse block.
    Fig 5: Installing Connectors To Relay And Fuse Block
    G10950759Courtesy of MAZDA MOTORS CORP.
  7. Install the clip.
    Fig 6: Identifying Relay And Fuse Block With Lower Cover And Clip
    G10950760Courtesy of MAZDA MOTORS CORP.
    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.
    Fig 7: Pressing Tab Of Relay And Fuse Block Lower Cover No. 1
    G10950761Courtesy of MAZDA MOTORS CORP.
  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.
    Fig 8: Identifying Relay And Fuse Block Lower Cover No. 1 And No. 2 With Tabs
    G10950762Courtesy of MAZDA MOTORS CORP.
  11. Install the bands.
    Fig 9: Identifying Relay And Fuse Block Or Bands
    G10950763Courtesy of MAZDA MOTORS CORP.
    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.
    Fig 10: Identifying Relay And Fuse Block, Stud Bolt, Pin, Bolt And Nut With Torque Specification
    G10950764Courtesy of MAZDA MOTORS CORP.
  13. Insert the relay and fuse block into the stud bolt.
  14. Install the bolt.
  15. Install the nut.
  16. Connect the connectors.
    Fig 11: Installing Wiring Harness To Relay And Fuse Block Hook
    G10950765Courtesy of MAZDA MOTORS CORP.
  17. Install the wiring harness to the relay and fuse block hook.
  18. Install the front body control module (FBCM). (Refer to FRONT BODY CONTROL MODULE (FBCM) REMOVAL/INSTALLATION .)
  19. Install all the relays and fuses.
  20. Install the relay and fuse block upper cover.
    Fig 12: Identifying Relay And Fuse Block Upper Cover
    G10950766Courtesy of MAZDA MOTORS CORP.
  21. Install the battery clamp, battery box and battery as a single unit. (Refer to BATTERY REMOVAL/INSTALLATION .)
  22. Connect the positive battery cable. (Refer to BATTERY REMOVAL/INSTALLATION .)
  23. Install the air cleaner, air hose and fresh air duct as a single unit. (Refer to INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T] .)
  24. Perform the "Verify relay and fuse block replacement". (Refer to VERIFY RELAY AND FUSE BLOCK REPLACEMENT .)
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