Opening up the Maxi Fuse Box for a Facelift C5

[Hell Razor5543]

Moderators, if this writeup is of use feel free to place it in the Resources section. I did not do this myself, as I thought that would be taking liberties.

You will need a 14mm socket and a blade screwdriver. If you need to replace a damaged 'output' connector you may need other tools, but in this case it turned out the main busbar was damaged, and replacing this is straight forward.

There are photographs showing the various stages. These are all my own work.

Remove the battery cover and the fuse box cover (this will need the blade screwdriver). Disconnect the battery (ideally as part of a BSi reset). Undo the 14mm nut connecting the battery leads to the main busbar, and lift off the wires. There are two 'latches' holding the whole fuse box in place. Using the blade screwdriver release these latches, and lift the whole fuse box up. There are two clips holding the Maxi fuse box to the main fuse box (I was able to photograph one clip, but as I don't have three hands (or an assistant) I could not get a good photo of the other clip). Release the Maxi fuse box from the main fuse box (again, with the screwdriver). There is a cover protecting the main busbar; carefully unclip this from the side opposite the Maxi fuses and lift it off.

There are eight Maxi fuses, and these need to be removed to allow the busbar to be removed. On MY C5 (yours may be different, so make sure you note down the order), going from left to right (engine to the left) they are 50A, 30A, 30A, 80A, 80A, 80A, 80A, 40A.

The busbar is held in place by a tongue next to the bolt, so lift it off by the opposite side. The bolt will come with it.

Assembly is a simple reverse of this procedure (despite what Haynes say!)