Mercury D9ZZ-14526-H Circuit Breaker Assembly

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The electrical circuits of the vehicle are protected by a combination of fuses, circuit breakers and fusible links. The fuse block is located below the left side of the dash. Later models have two fuse blocks, one for standard fuses located under the instrument panel on the left side of the dashboard and one for high current fuses in the engine compartment, adjacent to the battery. Disconnect the cable to the negative battery terminal before replacing high current fuses. On earlier models the fuses are tubular glass body types while on later models miniaturized fuses are employed. These compact fuses, with blade terminal design, allow fingertip removal and replacement. If an electrical component fails, always check the fuse first. The best way to check a fuse is with a test light. Check for power at the exposed terminal tips of each fuse. If power is present on one side of the fuse but not the other, the fuse is blown. A blown fuse can also be confirmed by visually inspecting it. Be sure to replace blown fuses with the correct type. Fuses of different ratings are physically interchangeable, but only fuses of the proper rating should be used. Replacing a fuse with one of a higher or lower value than specified is not recommended. Each electrical circuit needs a specific amount of protection. The amperage value of each fuse is molded into the fuse body. If the replacement fuse immediately fails, don't replace it again until the cause of the problem is isolated and corrected. In most cases, the cause will be a short circuit In the wiring caused by a broken or deteriorated wire.

The fuses and relays in the Power Distribution Box are replaced in the same manner as the fuse panel inside the vehicle. The power distribution box cover is hinged on one end and utilizes a retaining latch on the other. Simply release the latch and lift the cover up to gain access to the fuses and relays.

In addition to fuses, the wiring system incorporates fuse links for overload protection. These links are used in circuits which are not ordinarily fused. Fuse links are several wire gauges smaller than the circuit they are incorporated into and can be identified by their green or black color and molded color identification tag. The tag colors and corresponding gauges are as follows: green - 14 gauge, orange - 16 gauge, yellow - 17 gauge, red - 18 gauge, and blue - 20 gauge. It is important to note that fuse links cannot be repaired and must be replaced with a new fuse link of the same gauge, length, and insulation. To replace a blown fuse link, the battery ground cable should be disconnected and the damaged fuse link or fuse link eyelet terminal should be disconnected from the battery terminal of the starter relay. The damaged fuse link should be cut from the circuit and discarded, and the insulation from the circuit wire should be stripped back approximately 1/2 inch from the cut. The proper replacement fuse link should be determined and crimped into place in the wiring circuit, with any necessary eyelets being cut off. A resin core solder should be used at each end of the new link to ensure a good solder joint, and plenty of electrical tape should be used to cover the soldered joint to prevent any exposed wiring. Finally, a fuse link should be connected at the starter solenoid, the battery ground cable should be reconnected, and the circuit should be tested for proper operation.

A blown fuse can be identified by inspecting the broken metal element inside the glass tube.

The electrical circuits of the vehicle are protected by a combination of fuses, circuit breakers, and fusible links.

In addition to fuses, the wiring system incorporates fuse links for overload protection. These links are used in circuits which are not ordinarily fused. Fuse links are several wire gauges smaller than the circuit they are incorporated into and can be identified by their green or black color and molded color identification tag. The tag colors and corresponding gauges are as follows: green - 14 gauge, orange - 16 gauge, yellow - 17 gauge, red - 18 gauge, and blue - 20 gauge. It is important to note that fuse links cannot be repaired and must be replaced with a new fuse link of the same gauge, length, and insulation. To replace a blown fuse link, the battery ground cable should be disconnected and the damaged fuse link or fuse link eyelet terminal should be disconnected from the battery terminal of the starter relay. The damaged fuse link should be cut from the circuit and discarded, and the insulation from the circuit wire should be stripped back approximately 1/2 inch from the cut. The proper replacement fuse link should be determined and crimped into place in the wiring circuit, with any necessary eyelets being cut off. A resin core solder should be used at each end of the new link to ensure a good solder joint, and plenty of electrical tape should be used to cover the soldered joint to prevent any exposed wiring. Finally, a fuse link should be connected at the starter solenoid, the battery ground cable should be reconnected, and the circuit should be tested for proper operation.

When replacing blown fuses, it is important to replace them with the correct type. Fuses of different ratings are physically interchangeable, but only fuses of the proper rating should be used.

When replacing blown fuses, it is important to replace them with the correct type. Fuses of different ratings are physically interchangeable, but only fuses of the proper rating should be used.

The amperage value of each fuse is molded into the fuse body.

Bypassing the fuse with metal or foil can cause serious damage to the electrical system.