Diesel Data: Automotive Repair

Under-Dash Fuse/Relay Box Removal And Installation




Under-Dash Fuse/Relay Box Removal and Installation

Special Tools Required

- Relay Puller 07AAC-000A2A1 or 07AAC-000A1A0

USA models

NOTE: SRS components are located in this area. Review the SRS component locations Locations, and precautions and procedures Service and Repair before doing repair or servicing.

Removal

1. Do the battery terminal disconnection procedure.

2. Remove the dashboard lower cover Driver's Dashboard Lower Cover Removal/Installation.

3. Disconnect the connectors from the fuse side of the under-dash fuse/relay box (A).





4. Remove the mounting bolts, and pull the under-dash fuse/relay box away from the body.

5. Disconnect the connectors from the back side of the under-dash fuse/relay box, then remove the under-dash fuse/relay box.

6. Carefully remove the relays using the relay puller Testing and Inspection by prying under the base of the relay.

NOTE: Do not use pliers. Pliers will damage the relays, which could cause the engine to stall or not start.

Installation

7. Install the relays and connect the connectors to the under-dash fuse/relay box, then install the under-dash fuse/relay box in the reverse order of removal.

8. Install the removed parts in the reverse order of removal.

9. Do the battery terminal reconnection procedure steps 1 to 4.

10. Register the immobilizer system with the HDS Programming and Relearning.

NOTE: The imoes unit is built into the MICU which is part of the under-dash fuse/relay box. Because of this construction, the imoes must be registered, or the vehicle will not start.

11. Do the remaining steps of battery terminal reconnection procedure.

12. Confirm that all systems work properly.

Canada models

NOTE:

- SRS components are located in this area. Review the SRS component locations Locations, and precautions and procedures Service and Repair before doing repair or servicing.
- The under-dash fuse/relay box mounting screw is a one-way screw. Remove the one-way screw with pliers.

Removal

1. Do the battery terminal disconnection procedure.

2. Remove the dashboard lower cover Driver's Dashboard Lower Cover Removal/Installation.

3. Disconnect the connectors from the fuse side of the under-dash fuse/relay box (A).





4. Remove the mounting one-way screw (B), and pull the under-dash fuse/relay box away from the body.

5. Disconnect the connectors from the back side of the under-dash fuse/relay box, then remove the under-dash fuse/relay box.

6. Carefully remove the relays using the relay puller Testing and Inspection by prying under the base of the relay.

NOTE: Do not use pliers. Pliers will damage the relays, which could cause the engine to stall or not start.

Installation

7. Install the relays and connect the connectors to the under-dash fuse/relay box, then install the under-dash fuse/relay box in the reverse order of removal.

8. Install the removed parts in the reverse order of removal.

9. Do the battery terminal reconnection procedure steps 1 to 4.

10. Register the immobilizer system with the HDS Programming and Relearning.

NOTE: The imoes unit is built into the MICU which is part of the under-dash fuse/relay box. Because of this construction, the imoes must be registered, or the vehicle will not start.

11. Do the remaining steps of battery terminal reconnection procedure.

12. Confirm that all systems work properly.