This procedure covers the removal and replacement of a generic relay in the 2023 Chevrolet Bolt EUV, typically located in the underhood or interior fuse/relay boxes.

Warnings

Tools required

Parts

• Replacement relay × 1 — Match existing relay amperage and configuration

Preparation

1. Ensure vehicle is in Park with ignition off and key fob removed from vehicle
2. Locate the specific relay requiring replacement using the fuse/relay box diagram on the cover or owner's manual
3. Note the relay number, amperage rating, and terminal configuration for proper replacement
4. If relay is in underhood box, open hood and secure with prop rod
5. Determine if battery disconnection is necessary based on relay function (typically not required for simple relay replacement)

Procedure

1. 1

   Access the relay box
   Remove the fuse/relay box cover by releasing the retaining clips or tabs. For underhood boxes, lift the cover straight up. For interior boxes, press release tabs and pull cover away. Set cover aside in a clean area to avoid losing the diagram.
2. 2

   Identify the target relay
   Using the diagram on the fuse box cover or in the owner's manual, locate the specific relay to be replaced. Verify the relay position number matches your repair need. Relays are typically labeled with amperage and may be color-coded.
3. 3

   Test relay function (optional)
   If diagnosis is needed, use a multimeter to test relay coil resistance and continuity across terminals per service manual specifications. This helps confirm relay failure before replacement. Note that some relays may only be testable when energized.
4. 4

   Remove the failed relay
   Grasp the relay firmly with a relay puller tool or needle-nose pliers. Pull straight up with steady, even pressure to remove the relay from its socket. Do not rock or twist excessively as this may damage socket terminals. If resistance is encountered, verify no additional mounting hardware secures the relay.
5. 5

   Inspect relay socket
   Examine the relay socket for corrosion, damage, or contamination. Check that all socket terminals are present and not bent or pushed back. If corrosion is present, clean terminals with isopropyl alcohol and allow to dry completely. Verify socket pin tension is adequate for secure relay contact.
6. 6

   Verify replacement relay specifications
   Compare the new relay with the old relay to confirm matching amperage rating, terminal configuration, and physical dimensions. Verify the relay type (standard, mini, micro, or MAXI) matches the socket. Installing an incorrect relay may cause system malfunction or electrical damage.
7. 7

   Install the new relay
   Align the new relay terminals with the socket openings, ensuring proper orientation per the relay key or tab. Push the relay straight down into the socket with firm, even pressure until it seats completely and sits flush with adjacent relays. Verify the relay is fully engaged and cannot be easily lifted out.
8. 8

   Test relay operation
   If safe to do so without the cover installed, turn the ignition to ON or start the vehicle to verify the affected system operates correctly. For HVAC relays, activate climate control. For cooling fan relays, allow vehicle to reach operating temperature. Listen for relay clicking when system activates, confirming proper operation.
9. 9

   Reinstall relay box cover
   Position the fuse/relay box cover over the box, aligning all tabs and clips. Press firmly until all retaining clips engage with an audible click. Ensure the cover is fully seated and the diagram remains visible for future reference. Verify the cover is secure and will not vibrate loose.

Reassembly

1. Ensure all relay box covers are properly secured and latched
2. Close and latch the hood if working in the underhood fuse box
3. Verify no tools or parts were left in the engine compartment or interior

Verification

• Start the vehicle and verify all dashboard warning lights function normally during startup sequence
• Test the specific system controlled by the replaced relay to confirm proper operation
• Listen for unusual clicking, buzzing, or relay chatter which may indicate incorrect relay specification or socket damage
• If equipped, verify no diagnostic trouble codes are present using the vehicle information display
• For critical relays (fuel pump, cooling fan, HVAC), monitor system operation through at least one complete cycle

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