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Relay And Fuse Block: Installation: Procedure

  1. INSTALL RELAY AND FUSE BLOCK 
    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.
      NOTE:
      • If terminals are installed incorrectly, it could damage electrical accessories and burn wiring harnesses. When relocating terminals after replacing the fuse block, line up the fuse blocks of old and new parts and always verify each of the wiring harnesses in the wiring diagram so that the installation positions are correct.
      • 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.
      GTY487010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Flathead screwdriver
      *b Stopper
      *c Terminal
      *d Wiring harness
    2. Relocate all relay and fuse terminals to the new relay and fuse block.
      GTY494720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuse block (Old)
      *b Fuse block (New)
    3. Install the front wiring harness.
      GTY489674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front wiring harness *b Nut
      *c Relay and fuse block - -
      N*m (kgf*cm, ft.*lbf): Specified torque - -
    4. Install the nut.

      Torque: 5.3 N*m (54 kgf*cm, 47 in.*lbf) 

    5. Insert the front wiring harness connectors into the relay and fuse block.
      GTY488189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Relay and fuse block *b Front wiring harness connector
    6. Install the wiring harness clip to the relay and fuse block lower cover No. 2.
      GTY490006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Relay and fuse block lower cover No. 2
      *b Clip
    7. Insert all of the relay and fuse block middle cover tabs into the relay and fuse block lower cover No. 2.
      GTY487053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Relay and fuse block middle cover

      *a Relay and fuse block middle cover
      *b Tab
      *c Relay and fuse block lower cover No. 2
    8. Install the relay and fuse block lower cover No. 2 to the relay and fuse block middle cover.
    9. Insert all of the relay and fuse block middle cover tabs into the relay and fuse block lower cover No. 1.
      GTY488350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Relay and fuse block middle cover *b Relay and fuse block lower cover No. 1
      *c Relay and fuse block *d Tab
    10. Install the relay and fuse block lower cover No. 1 to the relay and fuse block middle cover.
    11. Install the wiring harness clips.
      GTY488535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Relay and fuse block *b Clip
    12. Insert the relay and fuse block into the stud bolts.
      GTY488977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stud bolt *b Relay and fuse block
    13. Install the nuts.

      Torque: 10.5 N*m (107 kgf*cm, 8 ft.*lbf) 

      GTY494318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
      *b Relay and fuse block
      N*m (kgf*cm, ft.*lbf): Specified torque
    14. Connect the emission wiring harness connectors.
      GTY490556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Emission wiring harness connector
      *b Relay and fuse block
    15. Press the emission wiring harness into the relay and fuse block hook.
      GTY490990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Relay and fuse block *b Emission wiring harness
      *c Hook - -
    16. Install all the relays and fuses.
    17. Install the relay and fuse block upper cover.
      GTY487806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Relay and fuse block upper cover - -
    18. Install the battery and the battery tray.

      Refer to INSTALLATION

    19. Install the air cleaner assembly.

      Refer to INSTALLATION

    20. Perform the "Verify Relay and Fuse Block Replacement".
  2. 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 (engine off).
    3. Verify that the fuse is not blown and the related wiring harness is not heated.
    4. Perform the initial settings for the following systems:
    5. Verify DTCs using the Techstream.
      • 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. Connect the negative battery cable.

      Refer to PROCEDURE - Step 1

    7. Start the engine and maintain the idle status.
    8. Operate all the switches of the interior/exterior lights of the vehicle and verify that all the lights illuminate and flash.
    9. Operate the audio, climate control, wiper switch, and selector lever (ATX) and verify that they operate correctly.
    10. 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. (ATX)
    11. Perform a road test and verify that low speed, acceleration, shift-up, and shift-down conditions are normal. (ATX)
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