Question about Saturn Ion

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Bad relay contact in under hood fuse box

The relays do not snap in their slots in the under the hood fuse box. In fact they wiggle and will in fact bump out and the car doesn't start. Can the contacts be tightened or do I need to add solder on the metal prongs of the relays.

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  • Saturn Master
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Bit of an unheard of problem. You might try just bending the relay prongs a tiny bit to make them fit snug. Was there a cover lid that fit tightly, and kept them in place? I suppose solder would be a good fix if you have to go that route, but I've never heard of this problem before.

Posted on Oct 25, 2012

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How to change the under the hood fuse box on a 2002 pontiac sunfire


slow down. the relay for the fan might just be sticking or have poor contacts. Make sure you don't just have a relay problem before replacing the whole panel.

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Before we go under the hood---did you check the cables/wires leading to the fuse box---and to the appropriate fuses---to make sure they are attached, not corroded or frayed?
If so, carry on-----

There are two relay boxes attached to the fender under the hood on the passenger side---one in front of the shock housing and a narrower one beside the battery.

There should be a label and/or description on top of or under the lid indicating which relay covers what circuits or equipment. In your case, there may be more than one culprit----so check them all.

BEFORE OPENING ANY RELAY BOXES or PULLING ANY PARTS----Disconnect the negative cable from the battery and secure it so that it cannot ground out against and body or engine part.

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Check each relay thoroughly.
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Once you find the culprit relay, take it with you when you go to the parts store so that they can match it exactly. Size and wire color matter.

Note: There is yet another relay box inside the car---attached to the firewall under the drivers side dashboard. Check those relays as well and make sure to wiggle the wires on each.

Note: In all cases, be sure to inspect the wires leading into and out of on the relay boxes themselves.
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I repeat: There may be more than one broken/burnt circuit, relay or fuse so check them all.

Once remedied, re-connect the negative cable to the battery and tighten it well.

Turn your ignition key to 'Accessories' then back to 'Off' three or four times before actually starting the car---just to reset the computer(s) (if you have one) .

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