bj40green
Tssss, tssss
I’m the happy owner of a ’78 BJ40. Unfortunately a PO removed the Fusible Links from my harness so a few circuits are unprotected. I’m not happy with that situation. I want them back in the electrical circuit.
I think I've read all the threads with the word "fusible" in it, but I can't find the the solution I'm looking for. I want the correct Fusible Links for my truck.
My FSM wiring diagram shows 2 FL's. One for the glow plugs and one for the rest of the circuits. The EPC however tells me that there is only one with part# 90982-08025. Hmmmm, That's problem number one.
Are there two FL's with the same part#, or are those different and is there an error in the EPC?
So I went to Pudy Motor (the official Toyota Importer) and asked if the FL is available. Answer...... No hay! which is Spanish for No Longer Available. Then I asked about the one or two in the EPC and FSM but now the guy looks at me if I'm the clown. As usual no help from Señor Toyota.
At this point I'm confused both the FSM wiring diagram and the EPC gives no information about the FL's. What wire size, rating, value or whatever. I have the part# but that is not available. If it was available, is it for the glow plugs or the other circuits? Now what?
I started a research to find out more about FL's. First about how they exactly work. (Thank you Google)
---- A Fusible Link is NOT A FUSE ----
It's function is to protect the wiring (harness/circuits) in the truck from burning, melting, frying, whatever you want to call it by long time overload (excessive current draw) or a short (to ground).
It doesn't burn out from a short time high current draw but from a long time high current draw before the wiring (harness) start melting.
A Fusible Link is a piece of wire, 6 to 9 inches long with a special insulation which will not burn or melt. You can't see if it's defective or not. You can test it by pulling on both ends. If it stretches the wire inside is burnt.
An AWG 10 wiring circuit is protected by an AWG 14 Fusible Link.
The FL is always 4 wire sizes or 2 AWG numbers higher then the circuit it protects.
For more info on this click here -> Catalog
Having this knowledge I ran into two new problems.
1st. Toyota's are metric and have their wiring in mm² and not AWG.
2nd. I still don't know what wire size the FL is that I need. The part number is telling me nothing.
So I started looking at other wiring diagrams of BJ's and HJ's and found out that in the later years Toyota added a code next to each FL.
I found (with the help of Lostmarbles/Tom) the following code's:
0.3 P
0.5 G
0.85 R
1.0 GR
1.0 Y
1.25 B
2.0 L
I suspected that the code was wire size in mm² and a letter for the color code. So 0.5 G means 0.5mm² Green, 0.85 R means 0.85mm² Red.
Thanks to Mr Google I found the first part (the wire size) confirmed as you can see in this picture.
This table is from a supplier that sells Fusible Link wire by the meter. Unfortunately he used his own color code so there is no similarity with the Toyota color code's.
If I set the color code aside i come to this table:
Fusible Link..................Protects circuits with wire size
mm²....AWG...................mm².....AWG
0.3.......22....................0.85......18
0.5.......20....................1.25......16
0.85.....18....................2.0........14
1.0.......17....................2.63......13
1.25.....16....................3.0........12
2.0.......14....................5.0........10
3.0.......12....................8.36........8
As you can see in the top picture in this page: Catalog a 2 sq. mm (AWG14) Fusible Link protects an AWG10 (5 sq. mm) circuit.
Next step: I can only meassure diameters and not mm² !
To be continued.......
I think I've read all the threads with the word "fusible" in it, but I can't find the the solution I'm looking for. I want the correct Fusible Links for my truck.
My FSM wiring diagram shows 2 FL's. One for the glow plugs and one for the rest of the circuits. The EPC however tells me that there is only one with part# 90982-08025. Hmmmm, That's problem number one.
Are there two FL's with the same part#, or are those different and is there an error in the EPC?
So I went to Pudy Motor (the official Toyota Importer) and asked if the FL is available. Answer...... No hay! which is Spanish for No Longer Available. Then I asked about the one or two in the EPC and FSM but now the guy looks at me if I'm the clown. As usual no help from Señor Toyota.
At this point I'm confused both the FSM wiring diagram and the EPC gives no information about the FL's. What wire size, rating, value or whatever. I have the part# but that is not available. If it was available, is it for the glow plugs or the other circuits? Now what?
I started a research to find out more about FL's. First about how they exactly work. (Thank you Google)
---- A Fusible Link is NOT A FUSE ----
It's function is to protect the wiring (harness/circuits) in the truck from burning, melting, frying, whatever you want to call it by long time overload (excessive current draw) or a short (to ground).
It doesn't burn out from a short time high current draw but from a long time high current draw before the wiring (harness) start melting.
A Fusible Link is a piece of wire, 6 to 9 inches long with a special insulation which will not burn or melt. You can't see if it's defective or not. You can test it by pulling on both ends. If it stretches the wire inside is burnt.
An AWG 10 wiring circuit is protected by an AWG 14 Fusible Link.
The FL is always 4 wire sizes or 2 AWG numbers higher then the circuit it protects.
For more info on this click here -> Catalog
Having this knowledge I ran into two new problems.
1st. Toyota's are metric and have their wiring in mm² and not AWG.
2nd. I still don't know what wire size the FL is that I need. The part number is telling me nothing.
So I started looking at other wiring diagrams of BJ's and HJ's and found out that in the later years Toyota added a code next to each FL.
I found (with the help of Lostmarbles/Tom) the following code's:
0.3 P
0.5 G
0.85 R
1.0 GR
1.0 Y
1.25 B
2.0 L
I suspected that the code was wire size in mm² and a letter for the color code. So 0.5 G means 0.5mm² Green, 0.85 R means 0.85mm² Red.
Thanks to Mr Google I found the first part (the wire size) confirmed as you can see in this picture.
This table is from a supplier that sells Fusible Link wire by the meter. Unfortunately he used his own color code so there is no similarity with the Toyota color code's.
If I set the color code aside i come to this table:
Fusible Link..................Protects circuits with wire size
mm²....AWG...................mm².....AWG
0.3.......22....................0.85......18
0.5.......20....................1.25......16
0.85.....18....................2.0........14
1.0.......17....................2.63......13
1.25.....16....................3.0........12
2.0.......14....................5.0........10
3.0.......12....................8.36........8
As you can see in the top picture in this page: Catalog a 2 sq. mm (AWG14) Fusible Link protects an AWG10 (5 sq. mm) circuit.
Next step: I can only meassure diameters and not mm² !
To be continued.......
Last edited: