Alero V6-3.4L VIN E (1999)
Fuse Types
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 J 39200 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 (approx. 9 inches) will not provide sufficient overload protection.
Refer to Splicing Copper Wire Using Splice Clips.
Splicing Copper Wire Using Splice Clips
TOOLS REQUIRED
J 38125-B Terminal Repair kit
1. Open the harness.
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If the harness is taped, remove the tape.
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To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
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If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
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Cut as little wire oft the harness as possible.
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Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from
bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
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The wire must be of equal or greater size than the original (except fusible link).
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The wire's insulation must have the same or higher temperature rating.
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Use general purpose insulation for areas that are not subject to high temperatures.
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Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
IMPORTANT: Use Cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact.
4. Strip the insulation.
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Select the correct size opening in the wire stripper or work down from the largest size.
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Strip approximately 7.5 mm (5/16 inches) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B Terminal Repair kit in order to determine the proper clip size
crimp tool and anvil.
6. Overlap the two stripped wire ends and hold them between thumb and forefinger.
