Relay & Fuse Box Dissection → Repairing Electrical Gremlins - Kia Forum

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post #1 of 34 (permalink) Old 06-12-2017, 02:48 AM Thread Starter
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Lightbulb Relay & Fuse Box Dissection → Repairing Electrical Gremlins

INTRODUCTION:

The purposes of this writeup, are: to Help you understanding the Relay & Fuse Box that came on the second generation of the Kia Sephia; how to find problems in its electrical distribution, and how to repair them in a safe and reliable way. This is an informative and illustrative writeup and I do not assume any responsibility for anything you might do with this information. Always be Careful before attempting any repairs.

If you don't have the Skills / Tools \ Knowledge, better let the professionals to do the repairs for you.


__________________________________________________ ________________________

First Part: The Relay & Fuse Box

The Relay & Fuse Box on the second generation of the Kia Sephia, is made by DELPHI, is very compact and complex at the same time; an interesting characteristic of it, is that all the Power input 12V (+) is received on a single point of it, which is a bolt called the "B+" and then, the power is distributed inside the Box, from that point, using a short metal plate for the main outputs, and using a bunch of copper wires for the rest of Relays & Fuses.

Prior to Repair anything, you need to Understand it and how it works; so I share here with you, Photos of the eight layers that compose the Relay & Fuse Box that I dissected, which belonged to a 2000 Kia Sephia, similar to our "KiaStein" so, let's Start!


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post #2 of 34 (permalink) Old 06-12-2017, 02:54 AM Thread Starter
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The first layer is the upper Cover:



Notice the B+ symbol on the lower right area, this will be our Guide.

Then, it comes the second layer, which is the inner Surface:



Here is where all the Relays & Fuses are Located.

There is a Bolt that receives the Power input at the B+ location.

An average Driver only will access these two layers.


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post #3 of 34 (permalink) Old 06-12-2017, 03:08 AM Thread Starter
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Then, after removing the inner Surface...



(the white squares are nuts, the box unscrews from upside down using a 7 mm socket)

...you will reach the third layer,

which is the
"intermediate connections" complex.

Here you can see it, to the left of the inner surface upside down:





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post #4 of 34 (permalink) Old 06-12-2017, 03:15 AM Thread Starter
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Arrow The "intermediate connections" complex

The "intermediate connections" complex...



...goes between the inner surface (or upper base), and...



...the lower Base, where the wiring plugs goes.


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post #5 of 34 (permalink) Old 06-12-2017, 03:32 AM Thread Starter
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Exclamation Here it gets... "interesting"

The "intermediate connections" complex, is a three layer plate, that unites the connections that comes and goes from the car's wiring, with the different Relays and Fuses; it has three plastic layers.

The center one has a bunch of metal pins that goes up and down thru the other two plastic layers; but also, there is a group of various, Non-insulated copper wires hiding on it; that delivers Power 12V
(+) to the Relays and Fuses, from the B+ terminal.





Also, said copper wires, delivers switching signals among relays:



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The non-insulated copper wires hiding underneath the "intermediate connections" complex, are held in place by the plastic layer, sandwiched in place, and they makes the complex interconnections by placing its ends pressed in small "V" shaped openings at the base of each metal pin.




So, if any of these copper wires that are only "touching" the metal pins on the complex, gets dirty, gets moisture, or gets loose and develops an electrical false contact; you Must change the Whole Box, because once you open this, it becomes terribly damaged, and thus means that it is designed from factory to be unrepairable.


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post #7 of 34 (permalink) Old 06-12-2017, 04:08 AM Thread Starter
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I really felt Dissapointed by DELPHI, the makers of these Boxes, because such level of Complexity, requires Better materials and Safer construction... I bet they wanted not only to save space, but also money, with these Boxes that always are working at High temperatures for prolongated periods of time, sometimes in hot humid weathers, and using A/C, Headlamps, Horn, etc... it is a Miracle that these old Kias are still on the Road... and the culprit of their electrical Gremlins, usually are these "Relay & Fuse" Boxes.

I've seen various Kia Sephias that already had lost their headlamp's Low beam, or the A/C's Blower, because the tiny Wiring working, heated the plastics enough to Melt he plugs and / or the plastic that holds the connecting pins, from the "intermediate connections" Complex; causing electrical false contacts and / or burning the connected ends of the Wires, making them to loose their hability to transfer the electrical current in the proper way...

Continue reading, I'll explain how to Fix those electrical issues, later.


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After the three layers that are the "intermediate connections" complex, comes the seventh layer, which is the Lower Base (or under base), it consists in a plastic plate where the aforementioned complex, sits above; and also it is where the four different Plugs with the car's wiring, comes to be attached below, on its underside.


Here you can see the Lower Base
(or under base) with some Plugs still attached:



(The tiny pins comes thru it, from the "intermediate connections" Complex,
these screws are holding everything together; needs a 7mm socket wrench)


Here's the same Lower Base, without the four main Plugs:



(The remaining two plugs, comes directly from the "B+" terminal,
and delivers non-switched, fused Power from the main -big- fuses' line.)


Here you can see in detail, one of the wiring Plugs:



The wires and the metal contacts are tiny.


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After all the above, comes the eight layer: the Lower Cover:



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Everything that was Pictured above, is on this collage Photo:



The parts are aligned here, in the way they goes assembled.


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