Hummer H1 Service Manual page 779

12-8 Electrical System
FUSIBLE LINK MAINTENANCE
The following procedure covers the replacement of fusible
links encountered through circuit diagnosis.
1. Disconnect battery ground cable.
2. Carefully remove old fusible link from termination
(alternator, power stud, starter).
3. Locate original wiring harness splice between fusible link
and wiring harness (Figure 12-7).
4. Cut fusible link splice on harness side. Do not splice into
original fusible link; this may be weakened and cause a
premature failure and repeat problem.
5. Identify the original fuse link size and length of fuse link
cut from vehicle.
6. Matching the wire size, cut a length of fusible link wire to
the total length cut from vehicle in Step 4. Be sure to
compensate for any harness wire removed with original
wire. This will avoid overtight wiring that may become
separated with normal operation.
WIRING
HARNESS
CUT HERE TO
REPLACE LINK
4-1-00
_________________________________________________________
HEAT SHRINK
TUBING
BUTT CONNECTOR
FUSIBLE
LINK
ORIGINAL
SPLICE
Figure 12-7: Fusible Link
NOTE: Fusible link is a wire with special insulation. It is im-
portant that replacement material be fusible link wire and it
should be labeled as such. The replacement fusible link should
be between six and nine inches long.
7. Install a new crimp on connector of the same type and size
as the original lug or connector. Seal connection with low
temperature heat shrink tubing.
8. Place a piece of heat shrink tubing onto the wire and
install a butt connector onto the fusible link.
9. Install the fusible link by connecting it to the wiring
harness with the butt connector and heat shrink tubing.
10. Connect terminal end to original location, alternator,
power stud, or starter. Reconnect battery ground cable and
check circuit(s) affected for proper operation.
BURNT SECTION
®
TERMINALS
S12-022.3