How to Replace the Fuse Box in a 1993 Geo Metro

Introduction

Replacing the fuse box in an older vehicle like a 1993 Geo Metro can seem daunting, but it's actually a straightforward repair that most owners can tackle themselves. The fuse box houses all the fuses that protect the various electrical circuits in your Metro. Over time, vibrations and heat cycling can cause the fuse box connections to fail. Replacing it restores full electrical function and prevents potentially dangerous shorts or fires.

In this guide, I'll walk you step-by-step through the entire fuse box replacement process for a 1993 Geo Metro. I'll cover safety preparations, locating and removing the old fuse box, installing the new fuse box, replacing the fuses, and testing your work. Let's get started!

Safety First

When working on any electrical system in a vehicle, safety should always be your top concern. Here are some important safety steps to take:

Disconnect the battery. Locate the battery under the hood and disconnect the negative terminal. This cuts power to the entire electrical system and prevents shorts.
Protect your eyes. Wear safety glasses when working under the dash near the fuse box. Debris or loose wires can fly up.
Avoid distractions. Do not attempt fuse box replacement while distracted. Working safely requires your full attention.
Review wiring diagrams. Consult the wiring diagram for your Metro to understand how circuits are routed.
Use proper tools. Lineman pliers, screwdrivers, trim removal tools, and a headlamp help safely access fuses.
Ask for help if needed. If you feel overwhelmed, ask an experienced mechanic friend to assist.

Locating the Fuse Box

On the 1993 Geo Metro, you'll find the main fuse box mounted to the driver's side of the dashboard, behind the small access panel.

To access the fuse box:

Open the driver's door and locate the oblong plastic panel on the side of the dashboard. It has a diagram of the fuse box printed on it.
Using a small screwdriver, pry out the panel to reveal the fuse box mounting screws behind it.
Remove the Phillips head screws securing the fuse box (usually two screws).
Pull the fuse box outward to access the rear connections.

Be gentle when removing the fuse box, as the connecting wires are brittle after years of heat cycling.

Removing the Old Fuse Box

With access gained to the rear of the fuse box, you can begin removing it:

Label each wire connection. Use masking tape to identify what each wire connects to before unplugging them.
Disconnect the wires. Press the locking tabs to release each connector and unplug the fuse box wires.
Unmount the fuse box. Remove any remaining screws or brackets securing the fuse box to the dashboard.
Inspect for damage. Look for signs of overheating, damaged or corroded terminals, and cracked housings before removing the old fuse box. Any issues indicate larger electrical problems may need addressed.
Remove the old fuses. Pull any remaining good fuses out of the fuse box to reuse or temporarily power accessories while the new fuse box is installed.

Thoroughly inspecting the wiring as you remove the old fuse box helps identify any other repairs needed in the Metro's electrical system.

Installing the New Fuse Box

Installation of the new fuse box involves reversing the removal steps:

Position the fuse box. Place the new fuse box in the same spot on the dashboard and align any screw holes.
Attach the fuse box. Reinstall any screws or brackets to securely fasten the fuse box in place.
Plug in the wires. Use your labels to guide reconnecting each wire to the proper fuse box terminals. Listen for a click as the locks engage.
Replace any damaged wires. Inspect the connecting wires again. Repair or replace any that are damaged before reconnecting them.
Reinstall the access panel. Screw the plastic fuse box access panel back in place over the new fuse box.
Reconnect the battery. Reconnect the negative battery cable when done.

It's crucial to double check all connections are secure, properly aligned with their terminals, and that no bare wires are exposed. This protects against dangerous shorts.

Replacing the Fuses

Before testing your work, all the appropriate fuses must be installed:

Consult the fuse diagram. Your Metro's fuse diagram, located on the fuse box cover, shows what fuse rating goes in each slot.
Insert the fuses. Press each fuse into the empty slots firmly until it clicks into place. Use your original fuses first, then any new replacement fuses.
Check for tight fit. Wiggle each fuse to verify it is held snugly. Loose fuses can heat up and fail.

Only install fuses specified for that slot in the diagram. Putting in a larger fuse than recommended can overload the circuit.

Testing the Repair

It's important to thoroughly test your work before driving the Metro:

Turn the key to accessory. Check that the accessories like the radio and power windows still function properly.
Start the engine. Listen for any unusual noises from under the dash that may indicate loose wires.
Turn on headlights and hazards. Verify exterior and interior lights are working on both sides.
Check gauges and dashboard. Make sure warning lights, fuel gauge, and other dashboard functions are restored.
Take a test drive. Drive the Metro cautiously around the block. Use all electrical accessories to confirm normal operation.

Finding any issues during testing gives you a chance to spot and re-repair problems immediately. If your fuse box replacement was successful, everything should function normally.

Conclusion

While fuse box replacement sounds complicated, it's actually a very approachable repair for most DIYers. The key steps are removing the old fuse box safely, installing the new fuse box properly, reconnecting all wires, replacing the fuses, and thoroughly testing operation. Patience and attention to detail goes a long way for electrical work. If at any point the job feels over your head, don't hesitate have a professional finish the fuse box installation. But with proper preparation, you can save significant money doing this repair yourself. Just always make safety the top priority.