Complete removal and replacement of the engine bay fuse box assembly on the 2023 Chevrolet Bolt EUV, including electrical disconnection, mounting hardware removal, and reinstallation with proper torque specifications.

Warnings

Tools required

Parts

• Engine bay fuse box assembly × 1 — Use OEM specification
• Fuse box cover × 1 — Included with fuse box or reuse existing
• Wire terminal dielectric grease × 1 — GM Part 12345579 or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle completely and remove key fob from interior
3. Open hood and secure with prop rod
4. Document all fuse positions and orientations with photos or notes
5. Ensure vehicle is unlocked as power locks will not function after battery disconnect
6. Allow all electrical systems to fully power down (wait 5 minutes after shutdown)

Procedure

1. 1

   Disconnect 12V auxiliary battery
   Locate the 12V auxiliary battery in the engine bay. Using the battery terminal wrench, loosen and remove the negative (-) terminal first, then the positive (+) terminal. Secure terminals away from battery posts using zip ties or tape. Wait a minimum of 2 minutes for all vehicle systems to discharge before proceeding.
   ⚠️Always disconnect negative terminal first to prevent short circuits. Do not allow tools to bridge battery terminals.
2. 2

   Label and photograph all electrical connections
   Before removing any connectors, take detailed photographs of the fuse box from multiple angles. Use labels or masking tape to mark each wiring harness connector with its position (e.g., 'Top Left', 'Bottom Right'). Document the orientation of any keyed connectors. This step is critical for correct reassembly on this vehicle which has multiple similar-looking connectors.
3. 3

   Remove fuse box cover
   Release the tabs securing the fuse box cover by pressing inward and lifting. On the Bolt EUV, there are typically 4 clips around the perimeter. Remove the cover screws if present using an 8mm socket. Set cover aside in a clean area.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Remove all fuses and relays
   Using the fuse puller tool (located inside fuse box cover), remove all fuses and relays from the fuse box. Place them in labeled compartments or on a diagram matching their original positions. Inspect each fuse for damage or corrosion. This ensures fuses are not lost and allows inspection of the fuse box interior.
5. 5

   Disconnect primary wiring harness connectors
   Locate the main wiring harness connectors on the rear and sides of the fuse box. Depress the locking tabs (typically red or gray) and carefully pull connectors straight away from fuse box. Do not pull on wires. There are usually 3-5 main connectors on this model. Support the connector body while releasing tabs to prevent damage.
   ⚠Connectors have internal locking mechanisms. Force during removal will break connector housings. Ensure tabs are fully depressed before pulling.
6. 6

   Disconnect ground straps
   Locate ground strap connections on the fuse box mounting area. Using a 10mm socket, remove ground strap bolts. Clean all ground contact surfaces with wire brush or contact cleaner to remove corrosion. Note the position and orientation of each ground strap for reinstallation. The Bolt EUV typically has 2 ground points near the fuse box.
   ℹ️Ground connections are critical for proper electrical system operation. Clean contact surfaces ensure reliable grounding.
   Torque spec

   Ground Strap Bolt14 Nm (10 lb-ft)

   Ground Bolt14 Nm (10 lb-ft)
7. 7

   Disconnect remaining terminal connections
   Remove any remaining bolted terminal connections to the fuse box using appropriate socket. These may include power distribution terminals or auxiliary connections. Remove terminal bolts completely and secure terminals away from work area. Apply light tension to wiring to identify any connections that may have been missed.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
8. 8

   Remove fuse box mounting bolts
   Locate the fuse box mounting bolts securing the assembly to the vehicle body/frame. On the Bolt EUV, there are typically 3-4 mounting bolts accessible from the top and side. Using a 10mm socket, remove all mounting bolts. Support the fuse box with one hand while removing the final bolt to prevent dropping.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
9. 9

   Remove fuse box assembly
   With all electrical connections and mounting bolts removed, carefully lift the fuse box assembly straight up and out of the engine bay. Check for any remaining wire ties or clips securing the assembly. Maneuver past nearby components taking care not to damage wiring harnesses or hoses. Place old fuse box on clean work surface.
10. 10

    Prepare new fuse box for installation
    Unpack new fuse box and verify part number matches vehicle specifications. Inspect all connector ports for shipping debris or protective caps that need removal. Transfer any mounting brackets from old fuse box to new unit if not pre-installed. Apply thin layer of dielectric grease to all connector terminals on the new fuse box to prevent corrosion.
11. 11

    Install new fuse box assembly
    Position new fuse box into mounting location, ensuring all wiring harnesses are routed correctly and not pinched. Align mounting holes with body/frame. Thread mounting bolts by hand first to ensure proper alignment. Once all bolts are started, torque in a crossing pattern to specification using torque wrench.
    ⚠Ensure no wiring harnesses are trapped under fuse box during installation. Check clearance around all sides before final tightening.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
12. 12

    Reconnect ground straps
    Reattach all ground straps to their original positions, ensuring contact surfaces are clean and metal-to-metal contact is achieved. Install ground strap bolts and torque to specification. Verify ground straps are not twisted and have adequate slack to prevent stress on connections.
    Torque spec

    Ground Strap Bolt14 Nm (10 lb-ft)

    Ground Bolt14 Nm (10 lb-ft)
13. 13

    Reconnect terminal connections and wiring harnesses
    Reconnect all bolted terminal connections using appropriate socket and torque to specification. Then reconnect all main wiring harness connectors to fuse box using your labels and photos as reference. Each connector should click audibly when fully seated. Gently tug on each connector to verify locking tab engagement.
    ⚠Incorrect connector placement will cause electrical system malfunctions. Verify each connector matches photos taken during disassembly.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
14. 14

    Reinstall fuses and relays
    Using your documentation from removal, reinstall all fuses and relays to their correct positions in the new fuse box. Ensure each component is fully seated. Replace any blown fuses with correct amperage replacements. Do not exceed original fuse ratings.
15. 15

    Reinstall fuse box cover and reconnect battery
    Position fuse box cover and secure with clips and screws if applicable. Torque cover screws to specification. Reconnect 12V auxiliary battery by connecting positive (+) terminal first, then negative (-) terminal. Torque battery terminal bolts to specification - do not overtighten as this can damage terminals.
    ⚠Connect positive terminal first during reconnection to prevent short circuits. Battery terminal bolts have low torque specification to prevent damage.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all connectors are fully seated and locking tabs engaged
2. Ensure no tools or parts remain in engine bay before closing hood
3. Double-check all ground connections are tight and contact surfaces are clean
4. Confirm fuse box cover is properly secured with all clips engaged

Verification

• Turn vehicle to ON position and verify dash warning lights illuminate normally then extinguish (except EV system ready)
• Check for any warning messages on instrument cluster related to electrical systems
• Test operation of critical electrical systems: headlights, turn signals, wipers, HVAC, power windows, and infotainment
• Verify power door locks and remote key fob functions operate correctly
• Use multimeter to verify 12V battery voltage reads 12.6-12.8V with vehicle off and approximately 14V with vehicle in READY mode
• Start vehicle and allow to run in READY mode for 5 minutes, monitoring for any electrical anomalies or warning lights
• Perform a test drive and verify all electrical accessories function normally under load

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