How to Replace the Fusible Links in a 1993 Geo Metro

Introduction

Replacing the fusible links in an older vehicle like a 1993 Geo Metro can be an intimidating task for a do-it-yourselfer. However, with some basic tools and a little bit of know-how, it's a straightforward job that can be accomplished in an afternoon. In this guide, I'll walk you step-by-step through the complete process of locating, testing, and replacing the fusible links in a 1993 Geo Metro.

What are Fusible Links?

Fusible links are a type of circuit protection device found in older vehicles like the Geo Metro. They are designed to protect against electrical shorts by "blowing" or melting when too much current flows through them. This breaks the circuit and prevents damage to the wiring harness or other components.

Some key things to know about fusible links:

• They look like colorful plastic-covered wires, usually found bundled together near the battery.

• Each one protects a different circuit (headlights, wipers, etc).

• When exposed to an overcurrent condition, the metal link inside overheats and separates, opening the circuit.

• They are one-time use - once blown, the link must be replaced.

Locating the Fusible Links

In a 1993 Geo Metro, the fusible link bundle will be found attached to the positive battery terminal.

To locate:

• Open the hood and prop it up.

• Find the positive battery cable where it attaches to the positive (+) battery terminal.

• Follow the cable back from the terminal and you will see a bundle of colored wires attached to it - these are the fusible links.

Testing the Fusible Links

Before replacing any fusible links, you'll want to test them to determine which ones need replacement. You can use a multimeter or test light.

To test with a multimeter:

• Set the multimeter to continuity or ohms setting.

• Touch the probe tips to both ends of a link.

• If meter shows continuity, the link is good.

• If no continuity, the link is blown and needs replacement.

To test with a test light:

• Clip test light to positive battery terminal.

• Touch probe tip to one end of the link, and clip to the other end.

• If test light comes on, link is good. If not, it's blown.

• Repeat for each colored link wire.

Removing the Bad Links

Once you've identified the blown fusible links, it's time to remove them:

• Use needle nose pliers to pry up the plastic connector caps at both ends of the bad link.

• Pull the link wire out of the connector. Caution: The exposed metal ends may be sharp!

• Remove any remaining metal pieces from the connectors using pliers or a small flat head screwdriver.

• Clean out the connectors with electrical contact cleaner spray.

Installing the New Links

Here's how to install your new fusible link wires:

• Slide heat shrink tubing over each end of the new link wire.

• Insert one end fully into empty connector, then connect other end.

• Position heat shrink over connectors and heat with hair dryer to seal.

• Use zip ties to bundle the new links back into the harness.

• Reinstall any plastic wire loom covers that were removed.

• Reconnect positive battery cable.

Verifying Repair

To be sure the new fusible links are working properly:

• Turn on various electrical accessories one by one, like headlights, wipers, etc.

• Check that items come on and multimeter shows continuity across each link.

• Go for a short test drive to confirm links stay intact when systems are operating.

And that's it - you've successfully replaced the blown fusible links in your 1993 Geo Metro! Taking the time to properly test, identify, and replace each damaged link will help keep your vehicle's electrical system protected for years to come.