GM Lumina/Silhouette/Transport APVs 1990-1999 Repair Guide

Fusible Links

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In addition to fuses, the wiring harness incorporates fusible links (in the battery feed circuits) to protect the wiring. Fusible links are 4 in. (102mm) sections of copper wire, 4 gauges smaller than the circuit(s) they are protecting, designed to melt under electrical overload. There are four different gauge sizes used. The fusible links are color coded so that they may be installed in their original positions.

  1. Fusible link B - Rust colored, charging and starting circuit, connected to the starter solenoid.
  2.  
  3. Fusible link C - Rust colored, TBI circuit, located at junction block, in the engine compartment, on the left side wheelhouse opening.
  4.  
  5. Fusible link H - Rust colored, charging and starting circuit, connected to the starter solenoid.
  6.  
  7. Fusible link J - RUST colored, coolant fan circuit, connected to the starter solenoid.
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  9. Fusible link Y - Rust colored, headlight circuit, located at junction block, in the engine compartment, on the left side wheelhouse opening.
  10.  
  11. Fusible link X - Rust colored, heater circuit, located at junction block, in the engine compartment, on the left side wheelhouse opening.
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  13. Fusible link X - Rust colored, TBI circuit, located at junction block, in the engine compartment, on the left side wheelhouse opening.
  14.  
  15. Fusible link X - Rust colored, charging and starting circuit, located at junction block, in the engine compartment, on the left side wheelhouse opening.
  16.  

REPLACEMENT



  1. Disconnect the negative battery terminal from the battery.
  2.  
  3. Locate the cause of the problem and repair before replacing the link.
  4.  
  5. Locate the burned out link.
  6.  
  7. Strip away the melted insulation and cut the burned link ends from the wire.
  8.  
  9. Strip the wire back 1 / 2 . (13mm) to allow soldering of the new link.
  10.  
  11. Using a new fusible link 4 gauges smaller than the protected circuit and approximately 10 in. (254mm) long, solder it into the circuit.
  12.  

Whenever splicing a new wire, always bond the splice with rosin core solder, then cover with electrical tape. Using acid core solder may cause corrosion.

  1. Tape and seal all splices with silicone to weatherproof repairs.
  2.  
  3. After taping the wire, tape the electrical harness leaving an exposed 5 in. (127mm) loop of wire.
  4.  
  5. Reconnect the battery.
  6.  

 
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