Damage to 175A Battery Harness Fusible Link Due to Incorrect Jump Start Connection

There have been warranty claims for battery harness replacements where the 175A fusible link has been reported as either an intermittent connection or has failed.

After analysis of returned parts, it has been determined that a current in excess of 175A has passed through the harness causing the fusible link to blow. Tests have confirmed that this failure mode can be reproduced by using the positive connection to the underhood fuse block as a jump start connection (refer to the graphic below).

The underhood fuse block positive connection (underneath the gray vinyl cover) should not be used as a connection during jump starting as this allows the starting current, which can be in excess of 200A, to pass through the harness containing the 175A fusible link.

Correct jump start connection posts are clearly identified in the G8 Owner Manual, page 8-90. The positive jump start post has a RED cover and is located near the left strut tower. The negative jump start post is between the left fender and the air cleaner box.

Damage to the fusible link caused by incorrect jump starting procedures is not covered by warranty and is considered to be a retail repair.

Where required, please advise the customer of the correct jump starting procedure.