Fusible Links and battery compartment wiring (WIP)

Mattlyon24

New Member
I was finally able to spend some time on it today and think I found the culprit... as many of you have suggested, I believe it’s the fusible link. After testing the starter, it’s fine. Here are some pics. Next step repair the fusible link.
 

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Fusible links aren't usually rated in amps*, because they're not intended to blow at a certain current. They're just intended to be a deliberate weak point in the wiring loom, the first piece of wire to melt if the circuit is overloaded (saves replacing the wiring harness). They're rated in cross sectional area, like the wiring loom wires.

Gert5XR.jpg

The four fusible links by the battery are usually 3x 0.5mm2 (green) and 1x 0.85mm2 (red). In American wire gauge 20gauge is 0.5mm2, but 0.85mm2 would be 17.5gauge which doesn't exist. 17 gauge (1mm2) would probably be ok, since it's still smaller than the 3mm2 wires it's protecting.

LOCK: power door locks, power windows.
DEF: rear windscreen defroster, rear blower.
LIGHT: Take a wild guess. That's right; headlamps, interior lamps, stop lamps, indicators...
IGN: Anything that's switched on by the ignition switch.

Fusible link wire colours are standardised, but as usual the best thing about standards are that there are so many to choose from. Japanese fusible link colours are different to US colours. Yay!

The important thing about fusible link wire is that the insulation is rated to contain the melted metal without catching on fire. Regular wire of the correct gauge would melt at the same time as a fusible link, but it might also set fire to the engine bay.

*You can calculate how many amps it'll take to melt a fusible link wire, you just need to know the resistance of the wire, its melting point, ambient temperature, and thermal conductivity of the insulation. You'll end up with a graph that says "at 40A, this wire will take 10 minutes to melt. At 60A, it'll take 3 minutes (etc. and for example)). Regular fuses also work this way a little (a 60A fuse will usually handle 80A for a few seconds, longer if it's cold out) but they're designed to minimise this "feature".
 
Thanks @Growlerbearnz ! Is length of the fusible link section critical? Example, if I replace 4" of fusible link is it best practice to replace with exactly 4" of new fusible link?

Here's what I'm grappling with. It's the 3 fusible links on the left side battery (I think they are all fusible links):

#1 - Big fat fusible link with black insulation (I think this is maybe for the glowplugs)
#2 - Green fusible link
#3 - Black with blue stripe fusible link

Anyone know what these 3 are out of curiousity? I'd like to label them for future reference, especially after I swap them out for different links with different colors.

IMG_5744.jpg
 
In theory the length is important, but it's not *that* important. I'd say as long as you're within an inch of the original wire it'll do the job.

#1 is indeed for the glow plugs, it's 1mm2 tin plated fusible link wire, but any 1mm2 fusible link wire will do. 16 gauge should do.
#2 is for the AC compressor and fans, it's 0.5mm2
#3 is the junction between the starter relay (under the drivers seat beside the glow plug relays) and the wire that goes to the starter motor solenoid. Not a fusible link ;-)
 
If you want to go OEM the fusible links are still available for a very reasonable price on Amayama.

#1 is MB328732 and is about $5
#2 is MB249345 and is about $3.50 (this is for the green .5mm wire, there is a different part number if you have .85mm red wire)
 
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