The fuse link is a short length of insulated wire contained in the alternator wiring harness, between the alternator and the starter relay. The fuse link is several wire gauge sizes smaller than the other wires in the harness. If a booster battery is connected incorrectly to the car battery or if some component of the charging system is shorted to ground, the fuse link melts and protects the alternator. The fuse link is attached to the starter relay. The insulation on the wire reads: FUSE LINK. A melted fuse link can usually be identified by cracked or bubbled insulation. If it is difficult to determine if the fuse link is melted, connect a test light to both ends of the wire. If the fuse link is not melted, the test light will light showing that an open circuit does not exist in the wire.
FUSE LINK REPLACEMENT
- Disconnect the negative battery cable.
- Disconnect the eyelet of the fuse link from the starter relay.
- Cut the other end of the fuse link from the wiring harness at the splice.
- Connect the eyelet end of a new fuse link to the starter relay.
Use only an original equipment type fuse link. Under no conditions should standard wire be substituted.
- Splice the open end of the new fuse link into the wiring harness.
- Solder the splice with rosin-core solder and wrap the splice with electrical tape. This slice must be soldered.
- Connect the negative battery cable.
- Start the engine, to check to see that the new connections complete the circuit.