2000-2001 Metro & Firefly Engine Fuse Box: Solving Electrical Gremlins
This guide covers the common failure points, symptoms, and replacement of the engine bay fuse box for the 2000-2001 Chevrolet Metro and Pontiac Firefly.
- This engine fuse box requires NO programming; it is a plug-and-play part.
- Failure often causes a no-start condition or multiple, seemingly unrelated electrical issues.
- Corrosion on the underside connectors is a very common problem; inspect and clean them before replacing the unit.
- A used OEM part is the most practical replacement, as new units are typically discontinued or sold only with the entire engine harness.
Is This Your Part?
This guide covers the main fuse and relay box located in the engine compartment for the 2000-2001 Chevrolet Metro and its Canadian twin, the 2000-2001 Pontiac Firefly. These vehicles were based on the Suzuki Swift platform, so this part is shared across all three models. It is responsible for housing the main fuses and relays that control the engine's essential functions.
This is different from the smaller fuse panel located inside the cabin, typically under the driver's side dashboard, which controls interior accessories like the radio and dome light.
Symptoms of a Failing Engine Fuse Box
A problem with the engine fuse box can be tricky to diagnose because it can cause a wide range of symptoms. Since it supplies power to so many different systems, failure often looks like a problem with another part.
- Engine Won't Start or Cranks But Won't Fire: This is the most common symptom. If the main relay or the fuel pump relay (or their circuits within the box) fails, the engine won't get the spark or fuel it needs to run.
- Multiple Unrelated Electrical Failures: You might experience several systems failing at once, such as the fuel pump, radiator fan, and headlights. This points to a central power distribution problem rather than individual component failures.
- Visible Corrosion or Damage: A visual inspection may reveal green or white crusty corrosion on the terminals, melted plastic around fuses or relays, or scorch marks.
- Burning Smell: A distinct electrical burning smell coming from the engine bay is a serious warning sign that a circuit is overheating within the fuse box.
- Intermittent Electrical Issues: The vehicle may stall randomly, or certain electrical functions may work one moment and not the next. This can be caused by poor connections or cracked solder joints inside the fuse box.
Known Issues for Metro & Firefly
On the 2000-2001 Chevrolet Metro and Pontiac Firefly, a common source of electrical gremlins is not always the fuse box itself, but the wiring and connections underneath it. Over time, moisture and dirt can accumulate under the box, causing corrosion on the harness connectors. This creates resistance and can lead to intermittent power loss or a complete no-start condition. Often, troubleshooting electrical issues on these cars leads to a mechanic recommending the removal of the fuse box just to inspect and clean the connections below it.
Pro Tip: Before condemning the fuse box, disconnect the battery and carefully unbolt the fuse box to inspect the large wiring connectors on the bottom. Cleaning these contacts with an electrical contact cleaner can sometimes resolve the issue without needing to replace the entire unit.
Buying a Used Fuse Box: What to Look For
Since new OEM fuse boxes for these models are generally discontinued and not sold separately from the main engine wiring harness, a quality used part is the most practical and affordable solution. Here’s what to inspect before you buy.
- Check for Corrosion: This is the #1 killer of these parts. Look for any signs of green or white powder on the fuse terminals, relay sockets, and especially on the large pins of the connectors on the underside of the box. A part with any visible corrosion should be avoided.
- Inspect for Heat Damage: Look closely at the plastic around each fuse and relay socket. Any melting, warping, or discoloration is a red flag that a circuit was overloaded. This indicates internal damage to the box's bus bars, and it should not be used.
- Verify Part Numbers: The best way to ensure compatibility is to match the part number from your original fuse box. Known OEM part numbers include GM (91173437, 91173757) and Suzuki (36730-60G00, 36730-60G10). The number is typically stamped on the side or bottom of the plastic housing.
- Examine for Physical Damage: Check for cracks in the plastic housing or broken mounting tabs. While a small crack might be cosmetic, a serious break could allow water to enter and cause future corrosion.
- Get the Pigtails: If possible, get the yard to include a few inches of the wiring harness connectors (pigtails). If any of your vehicle's connectors are corroded, having a clean replacement to splice in can be a lifesaver.
Programming and Installation
Good News: This part does not require any programming or flashing. The engine fuse box is a non-intelligent component that simply routes power. It is a direct plug-and-play replacement.
Replacement Overview
Replacing the engine fuse box is a straightforward job that is feasible for a DIY mechanic with basic tools. The process generally takes about an hour.
- Disconnect the Battery: Always disconnect the negative battery terminal first to prevent electrical shorts.
- Remove the Cover: Unclip the plastic cover from the top of the fuse box.
- Disconnect Power Leads: There will be one or more main power wires coming from the battery or alternator, usually held on with 8mm or 10mm nuts. Remove these.
- Unbolt the Fuse Box: Remove the bolts that secure the fuse box housing to the vehicle's chassis.
- Disconnect Harness Connectors: Lift the fuse box up. The main wiring harnesses connect to the bottom of the box. Each connector has a release tab that must be pressed to unplug it. This is often the most time-consuming step.
- Install the New Box: Installation is the reverse of removal. Plug in all harness connectors securely, bolt the new box in place, re-attach the main power leads, and finally, reconnect the battery.
Cost of a Replacement Fuse Box
Pricing can vary, but this is a relatively inexpensive part to source from the used market.
| Part Type | Estimated Cost | Notes |
|---|---|---|
| Used OEM | $25 - $75 | From a salvage yard or online seller. This is the most common and recommended option. |
| New Aftermarket | Not Available | Direct-fit replacements for the full assembly are not commonly manufactured. |
| New OEM | $200+ (If Found) | Likely discontinued and only available as part of the complete engine wiring harness, making it very expensive and hard to find. |
| Shop Labor | $100 - $200 | Typically 1 to 1.5 hours of labor for diagnosis and replacement. |
Frequently Asked Questions (FAQ)
Do I need to program a replacement fuse box?
No. The engine fuse box for the 2000-2001 Metro and Firefly is a simple power distribution center and does not contain any software. It does not need to be programmed or coded to the vehicle.
Can I use a fuse box from a Suzuki Swift?
Yes, most likely. The Chevrolet Metro and Pontiac Firefly of this generation are rebadged Suzuki Swifts. As long as the part number and connector layout match your original part, a fuse box from a 2000-2001 Suzuki Swift should be compatible.
What OBD-II codes are caused by a bad fuse box?
A failing fuse box itself does not store trouble codes. However, its failure can cause other modules to report faults. For example, an intermittent fuel pump circuit could cause lean codes like P0171. A complete failure might result in communication codes (like U0140) or, more commonly, a complete inability to communicate with the vehicle's computer at all.
My fuses are all good, but a circuit is still dead. Could it be the fuse box?
Yes. The problem can be the internal connections within the fuse box or the wiring connectors on the underside. The metal pathways that connect the fuse terminals to the wiring harness can crack or corrode, creating an open circuit even with a good fuse.
Technical Specifications
OEM Part Numbers: 91173437 91173757 36730-60G00 36730-60G10
Houses main system relays and high-amperage fuses for engine and chassis components. Connects directly to the main engine wiring harness via multiple underside connectors.
The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
- Chevrolet Metro:
- Pontiac Firefly: