ELECTRICAL-BODY AND CHASSIS 12-2
FJg.
1 - Fuse Panel Assembly
All power window and tailgate circuits require the igni-
tion switch to be "ON" to open or close the windows un-
like past model designs which were operated independ-
ently of the ignition switch.
The windshield wiper and washer switch is new in that
washer button in the center of the knob has been deleted
and its function will be accomplished by pushing the knob.
A set screw is used to retain the knob to the shaft.
In addition to fuses, the wiring harness incorporates
fusible links to protect the wiring. Links are used rather
than a fuse in wiring circuits that are not normally fused,
such as the ignition circuit. Fusible links in the Chevro-
let wiring are four gauge sizes smaller than the cable it
is designed to protect. The links are marked on the
insulation with wire gauge size because of the heavy insu-
lation which makes the link appear a heavier gauge than it
actually is.
Engine compartment wiring harness incorporate sev-
eral fusible links. Each link is identified with its gauge
size.
A fusible link is a length of special wire (normally
four wire gauges smaller than the circuit it is protecting)
used in wiring circuits that are not normally fused, such
as the ignition circuit. The same size wire with a spe-
cial hypalon insulation must be used when replacing a
fusible link.
The links are:
1.
The pigtail lead at the battery positive cable (except
Corvette) is a 14 gauge, brown fusible link protecting
the 10 gange battery charging circuit. This wire is
an integral part of the battery cable assembly and
servicing requires replacing the complete battery
cable assembly. On Corvette models this link is
installed as a molded splice at the solenoid "Bat"
terminal and servicing requires splicing in a new
link.
2.
A 16 gauge black fusible link is located at horn relay
to protect all unfused wiring of 12 gauge or larger.
It is a serviceable piece with an in-line connector
and is not integral with the wiring harness.
3.
The generator warning light and field circuitry (16
gauge wire) is protected by a fusible link (20 gauge
orange wire) used in the "battery feed to voltage
regulator #3 terminal" wire. The link is installed
as a molded splice in the generator and forward lamp
harness and is serviced by splicing in a new 20 gauge
wire as required.
4.
The ammeter circuit on all models is protected by
two orange, 20 gauge wire fusible links installed as
molded splices in the circuit at the junction block or
the solenoid "Bat" terminal (Corvette only) and at the
horn relay. Each link is serviced by splicing in a
new 20 gauge wire as required.
The wiring harnesses use a standarized. color code
common to all Chevrolet vehicles. Under the color code,
the color of the wire designates a particular circuit. The
harness title indicates the type of harness, single of mul-
tiple wire, and also describe the location of the harness.
The body harness is a flat, solid wire assembly and is
routed through the vehicle near the center of the body.
Composite wiring diagrams (figs. 104 thru 124) are in-
cluded at the end of this section.
MAINTENANCE AND ADJUSTMENTS
Maintenance of the lighting units and wiring system
consists of an occasional check to see that all wiring
connections are tight and clean, that the lighting units are
tightly mounted to provide good ground and that the head-
lamps are properly adjusted. Loose or corroded con-
nections may cause a discharged battery, difficult start-
ing, dim lights, and possible damage to generator and
regulator. Wire harnesses must be replaced if insulation
becomes burned, cracked, or deteriorated. Whenever it
is necessary to splice a wire or repair one that is bro-
ken, always use solder to bond the splice. Always use
rosin flux solder on electrical connections. Use insulat-
ing tape to cover all splices or bare wires.
When replacing wires, it is important that the correct
size be used. Never replace a wire with one of a smaller
size.
Each harness and wire must be held securely in place
by clips or other holding devices to prevent chafing or
CHEVROLET CHASSIS SERVICE MANUAL
