Chevrolet Chevette/1000 1976-1988 Repair Guide

Fusible Link

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Fig. Fig. 1View of a fuse box for 1976-80 vehicles. Note that the flasher is indicated by an arrow



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Fig. Fig. 2View of a fuse panel for 1981-88 vehicles



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Fig. Fig. 3Fuel panel location-1984 Chevette shown



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Fig. Fig. 4Fusible link replacement

In addition to circuit breakers and fuses, the wiring harness incorporates fusible links to protect the wiring. Links are used rather than a fuse in wiring circuits that are not normally fused, such as the ignition circuit. Fusible links are color coded red in the charging and load circuits to match color coding of the circuit they protect. Each link is four gauge sizes smaller than the cable it is designed to protect and are marked on the insula tion with wire gauge size because the heavy insulation makes the link appear a heavier gauge than it actually is.

Engine compartment wiring harnesses incorporate several fusible links. The same size wire with special hypalon insulation must be used when replacing fusible link.

The links are:

  1. A molded splice at the starter solenoid "Bat" terminal, 14 gauge red wire. Servicing requires splicing in a new link.
  2.  
  3. A 16 gauge red fusible link is located at junction block to protect all unfused wiring of 12 gauge or larger. The link is terminated at the bulkhead connector.
  4.  
  5. The generator warning light and field circuitry (16 gauge wire) is protected by a fusible link (20 gauge wire) is protected by a fusible link (20 gauge red wire) used in the "battery feed to voltage regulator #3 terminal" wire. The link is installed as a molded splice in the circuit at the junction block. Service by splicing in a new 20 gauge wire.
  6.  
  7. The ammeter circuit is protected by two red 20 gauge wire fusible links installed as molded splices in the circuit at the junction block and battery to starter circuit. Service by splicing in new gauge wires.
  8.  

REMOVAL & INSTALLATION



  1. Disconnect the battery ground cable.
  2.  
  3. Disconnect the fusible link from the junction block or starter solenoid.
  4.  
  5. Cut the harness directly behind the connector to remove the damaged fusible link.
  6.  
  7. Strip the harness wire approximately 1 / 2 ".
  8.  
  9. Connect the new fusible link to the harness wire using a crimp on connector. Solder the connection using rosin core solder.
  10.  
  11. Tape all exposed wires with plastic electrical tape.
  12.  
  13. Connect the fusible link to the junction block or starter solenoid and reconnect the battery ground cable.
  14.  



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Fig. Fig. 5Troubleshooting Basic Windshield Wiper Problems



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Fig. Fig. 6Troubleshooting the Heater



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Fig. Fig. 7Troubleshooting Basic Turn Signal and Flasher Problems



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Fig. Fig. 8Troubleshooting Basic Dash Gauge Problems



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Fig. Fig. 9Troubleshooting Basic Lighting Problems

 
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