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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 flat head 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.
    G11432432Courtesy of MAZDA MOTORS CORP.
  2. Relocate all relay and fuse terminals to the new relay and fuse block.
    G11432433Courtesy of MAZDA MOTORS CORP.
  3. Install the wiring harness.
    Fig 1: Relay And Fuse Block Bolt With Torque Specification
    G11432434Courtesy of MAZDA MOTORS CORP.
  4. Install the bolt.
  5. Install the relay and fuse block middle cover to the relay and fuse block.
    G11432435Courtesy of MAZDA MOTORS CORP.
  6. Install the connectors to the relay and fuse block.
    G11432436Courtesy of MAZDA MOTORS CORP.
  7. Install the clip.
    G11432437Courtesy 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 flat head 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.
    G11432438Courtesy 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.
    G11432439Courtesy of MAZDA MOTORS CORP.
  11. Install the bands.
    G11432426Courtesy 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 2: Relay And Fuse Block Bolt And Nut With Torque Specification
    G11432441Courtesy 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.
    G11432442Courtesy of MAZDA MOTORS CORP.
  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.
    G11432443Courtesy of MAZDA MOTORS CORP.
  21. Install the battery clamp, battery box and battery as a single unit. (See BATTERY REMOVAL/INSTALLATION .)
  22. Connect the positive battery terminal. (See BATTERY REMOVAL/INSTALLATION .)
  23. Install the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T] .)
  24. Perform the "Verify relay and fuse block replacement". (See Verify relay and fuse block replacement .)
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