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You are watching: How to remove toyota alternator fuse


Hello eveyone,I just replaced an alternator on my 2013 Sienna LE. After I spent three afternoon after work to complete this work and started the engine and discovered that the alternator fusible link fuse was blew out because I forgot to disconnect the negative battery terminal before I did the work. Now I am trying to remove this 140 amp fuse located inside the fuse box under the hood but no luck so far. I believe it is bolted to the bottom of the high voltage cable so it looks like I have to disassembly the two halve of the box in order to access to the bottom bolt. I have been trying to find a way to disconnect these two halve but no luck so far. Does anybody ever run into this problem before and may be have a trick to do this?Any help would greatly appreciate it.Tung Le
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I have never had a GEN3 apart but they are a PITA. The 140A fuse pushes into the fuse box and has to be unbolted as you know. I had a quick look at my van (2011). Looks like the battery and maybe the ECM will have to come out and maybe the airbox. Once they are out of the way you have to remove the bolts that hold in the fuse box. Now you should be able to work on it. The whole bottom of the box comes off. There are little tabs that need to be pushed in to allow the fuse block to push in. you may need several small screwdrivers to release the tabs from the top. I tried to look around for diagrams on the net. I will keep looking.
I have never had a GEN3 apart but they are a PITA. The 140A fuse pushes into the fuse box and has to be unbolted as you know. I had a quick look at my van (2011). Looks like the battery and maybe the ECM will have to come out and maybe the airbox. Once they are out of the way you have to remove the bolts that hold in the fuse box. Now you should be able to work on it. The whole bottom of the box comes off. There are little tabs that need to be pushed in to allow the fuse block to push in. you may need several small screwdrivers to release the tabs from the top. I tried to look around for diagrams on the net. I will keep looking.
--------------------------------------------Hi 3Wheelerguy,Thank you so much for your reply. I spent a good 3 1/2 hr to remove airbox, ECM and other cable connections as you mentioned above. This gives me some room to access to the tabs around the fuse box and able to separate the top and bottom fuse box housing. Since it is getting late, I stopped at this point and plan to come back and hope able to turn the box up side down so that I can see and access to the nut and unscrew it. I will give the update tomorrow and let you know how it goes.Thank again for your post.

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So, I found this post trying to figure out how to replace the 140 amp fusible link "fuse" in the 2011+ Sienna van. This answer is left incomplete so here is the completion from my perspective. 1st: original problem: I shorted out my alternator/battery connection to ground while replacing my ac clutch (that"s another story). This blew the 140 amp fusible link ("FL Main" in Toyota wiring diagram parlance). Note, if this happens to you, your Sienna will lock up with no EPS, no ABS, no VCS, no power windows or side mirrors, no wipers, no turn signals (hazards will work), locked in park, no AC, no radio, etc. This is because this fuse powers the interior fuse box and the CAN and LIN networks (my educated guess).This little fusible link critter is hard to replace but not expensive (PN 9098208286). So I did the following:1. Removed battery.2. Loosened ECU bracket.3. Loosened driver side headlight.4. Removed smaller ECU connector (to give more room to move the fuse box)5. Removed three bolts holding down fuse box.6. Removed ground connection and other connector to something behind headlight.7. Removed headlight bulb connections.8. Cut two slip ties reinforcing wire bundleds to fuse box.9. Trimmed lock tabs off fuse box locks by main wire bundle entrance.10. With small screwdriver, unlock and push into fuse box the fuse holder assemblies/connectors. Doing this will allow the top of the fuse box to move out of the way. Doing this before splitting the fuse box is helpful. Most of the relays need to be removed to allow the connector bases to push into the interior of the fuse box.11. Used flat blade screwdriver and toothpicks to unlock the tabs holding the two halves of the fuse box together.12. Separate top of fuse box from bottom of fuse box just enough to get to the bolts securing the 140 amp fuse. One bolt is 10mm the other is 8 mm. 13. Replace 140 amp fusible link.14. Reassemble in reverse order.Later I will post pictures of the surgery.Cheers! Hang in there all you DYI"ers.