STS AWD V6-3.6L (2007)
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or
electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it
must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will
identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough
pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be
vibration related. Manipulation of a circuit can consist of a wide variety of actions, including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to
the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component
commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move
related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system
operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In
these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too
short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while
