Battery Junction Box (BJB)

Battery Junction Box (BJB)
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures

Removal
1 Remove the bumper armature.
For additional information, refer to Front Bumper Front Bumper
2 Remove the air cleaner housing.
For additional information, refer to Air Cleaner Service and Repair
3 Remove the secondary bulkhead center panel.
For additional information, refer to Secondary Bulkhead Center Panel - 3.2L Service and Repair
4 Remove the brake booster.
For additional information, refer to Brake Booster Service and Repair
5 Remove the ABS module.
For additional information, refer to Anti-Lock Brake System (ABS) Module Service and Repair
6 Remove both headlamps.
For additional information, refer to Headlamp Assembly Service and Repair
7 Remove the engine upper support insulator.
For additional information, refer to Engine Upper Support Insulator Engine Upper Support Insulator
8 Remove the glove compartment lid.
For additional information, refer to Glove Compartment Service and Repair

NOTE:
RHD illustration shown, LHD is similar.
9 Remove both front fender splash shields.

10 Release the harness and withdraw into engine bay area.

11 Release the harness cover and withdraw harness into engine bay area.

12 Repeat for both sides.

13 Unclip the windscreen heater electrical connector from the plenum side extension panel and remove the panel.

NOTE:
LHD illustration shown, RHD is similar.

14 Release the engine compartment harness from clip securing it to the vehicle bulkhead.

NOTE:
RHD illustration shown, LHD is similar.

NOTE:
RHD illustration shown, LHD is similar.

15 RH side front: Release the ABS sensor lead and disconnect the electrical connector.

NOTE:
RH illustration shown, LH is similar

16 Release the LH side repeater from the vehicle body and disconnect the electrical connector.

NOTE:
RHD illustration shown, LHD is similar.

NOTE:
RHD illustration shown, LHD is similar.

17 Unclip the harness tray from the vehicle bulkhead and route the RHS of the harness around the brake pipes into the LHS of the engine bay.

NOTE:
RHD illustration shown, LHD is similar.

NOTE:
LHD illustration shown, RHD is similar.

NOTE:
RHD illustration shown, LHD is similar.

NOTE:
RHD illustration shown, LHD is similar.

18 With assistance, release the harness.

NOTE:
With assistance remove the component.

19 Remove the engine compartment harness.

Installation
1 Place harness to vehicle plenum, feed connectors into inside of vehicle and install grommet. Use assistance inside vehicle to pull connectors through.
2 Secure harness tray clips and secure rubber grommet to vehicle body.
3 Install and secure fusebox to body.
Torque to: 10 Nm
4 Install the engine mounting plate.
M8: 24 Nm
M12: 80 Nm
5 Secure the engine harness to the fusebox.
6 Connect the two electrical connectors to the BJB.
7 Install and secure the battery lead to the fusebox and install the small battery lead cover.
Torque to: 10 Nm
8 Secure the 3 earth points and secure the harness clips to the vehicle body.
Torque to: 10 Nm
9 Secure the battery lead to the battery terminal clamp.
Torque to: 25 Nm

10 Install the fuse box cover.

11 Install the harness cover to the suspension turret.

12 Feed harness under the air
cleaner duct and secure the duct to the grommet.

13 Secure headlamp and bumper harness clips.

14 Connect the height sensor electrical connector and secure the harness with the clips.

15 Install headlamp mounting plate.
Torque to: 10 Nm

16 Connect the side repeater electrical connector.

17 Connect the heated washer jet electrical connection and secure the harness to the vehicle body.

18 Connect the ABS sensor and secure the harness to the vehicle body.

19 Secure the washer pipe to the harness and
secure the harness to the body.

20 Connect the crash sensor electrical connectors.

21 Connect the the bonnet lock electrical connector

22 Secure the harness to the body and then secure the bonnet release cable to the harness.

23 Secure the washer pipe to the washer bottle.

24 Install the washer bottle and connect the electrical connections.
Torque to: 10 Nm

25 Secure the 3 ground cables to the vehicle body.
Torque to: 10 Nm

26 Secure the harness to the vehicle
body.

27 Connect the coolant level sensor electrical connector.

28 Install the RH secondary bulkhead mounting bracket.
Torque to: 10 Nm

29 Install the inner plenum plate and secure the electrical connector to the plate.

30 Connect the heated screen RH electrical connector.

31 Connect the BBUS electrical connector.

32 Connect the A/C pressure switch electrical connector.

33 Secure the engine compartment harness to the vehicle bulkhead.

34 Secure the harness tray to the LHS of the vehicle bulkhead.

35 Connect the LH heated screen electrical connector and secure the harness to the vehicle body.

36 Feed the harness into the LH wheel arch and secure the grommet.

37 Install the ABS modulator bracket.
Torque to: 25 Nm

38 Install the LH side repeater lamp and secure the clips to the vehicle body.

39 Connect the rear washer pipe.

40 Connect the ABS sensor electrical connector and secure the harness to the vehicle body.

41 Connect the two electrical connectors to the CJB.

42 Connect the main engine compartment harness to the instrument panel harness and close the cover.

43 Connect the main engine compartment harness to the headlamp levelling ECU.

44 Connect the 3 floor harness electrical connections.

45 Install the fuse cover and refit the sound deadening sheet.

46 Install the LH fender splash shield.
Torque to: 6 Nm

47 Install the glove compartment lid.
For additional information, refer to Glove Compartment Service and Repair

48 Install the engine upper support insulator.
For additional information, refer to Engine Upper Support Insulator Engine Upper Support Insulator

49 Install both headlamps.
For additional information, refer to Headlamp Assembly Service and Repair

50 Install the ABS module.
For additional information, refer to Anti-Lock Brake System (ABS) Module Service and Repair

51 Install the brake booster.
For additional information, refer to Brake Booster Service and Repair

52 Install the secondary bulkhead center panel.
For additional information, refer to Secondary Bulkhead Center Panel - 3.2L Service and Repair

53 Install the air cleaner housing.
For additional information, refer to Air Cleaner Service and Repair

54 Install the bumper armature.
For additional information, refer to Front Bumper Front Bumper