70 series fusible link install? (1 Viewer)

[ToyotaMatt]

Per the FSM it is a red wire, for the headlights. Probably a 16g wire. It'll be part of the bundle coming down the fender from the firewall. The PO may have spliced a different color onto it so you might have to follow the harness back a bit to find it.

On my RHD it comes out of the firewall on the left-hand (passenger) side to the battery also located in that side.

Not sure about yours.

i do have all the oem connectors discussed in this thread thus far , and all the ring terminals as well too ,

thanks for the clarify on mixing up the fellow member and there particular fusible links set-up , i might have got lost above when the discussion got into substitutes and the improvised topic ?


is a format , i don't really make or reproduce anything toyota currently makes as in a part # like a fusible link , but your right the disc. / NLA status can happen any day now or many years in the future ?

but it never ceases to amaze me the continuing in-flux of new and never seen before Fusible Links applications and end of the day part #'s that MUD Advance search feature has zero results when i apply them to it ,

forget GOOGLE , MUD advance search feature key word search is the place to go ......

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[svsisu]

the BLUE fusible link wire is a thicker gauge or MM. SQ. then the YELLOW is ,

Neither YAZAKI or SUMITOMO offer the YELLOW JIS Fusible Link wire any longer , but substituting it for the BLUE in your case , i am not following the GLOW PLUGS circuit ?

what did originally have from the factory ? .

what has changed or been modified in your particular case that creates the need / allows your circuit protection level to be increased like i am explaining here as a question ?

matt

DM coming later

 

[TreadingLight]

My remaining challenge is trying to figure out where the female, harness side plug is supposed to be wired in on my truck, because I think the PO cut it out. If anyone has clear pics of the connection points, would love to see them.

Looking at your photo, what's that connected to your battery with the disintegrating yellow insulator? Could that be spliced to your headlight wire?

 

[JuanJ]

I think you may have mixed up the two posters - @Redline70 has an fzj7x with a 2 circuit fusible link. @svsisu is describing his similar-but-different hzj7x with the glow plug circuit.

From the pictures & the FSM, it looks to me like @Redline70 needs an engine harness side 1-way connector (housing & terminal) to replace the one the PO hacked off. If fzj7x fusible links are still available, from @ToyotaMatt or from Toyota, then ideally he'd get the matching connector so the fzj7x fusible link will plug right in.

@ToyotaMatt - do you have fzj7x fusible links with the round connector like @JuanJ posted in his picture above? And the matching engine-side connector to restore @Redline70 's?

If so I'd recommend getting several links and having a small stockpile as Toyota will eventually stop making them, requiring people to get creative. This is a challenge right now in the 60-series.

If fzj7x fusible links are not available, then it's time to get a little creative. If I were to design my own, I would find the wire that would be going into a connector (if it hadn't been brutalized by it's PO), probably cut the ring terminal off and discard the junction box on the other one, and make my own links using fusible link wire matching Toyota's diameters in the FSM I posted above, and put the waterproof connector of your choosing onto the engine harness. A metripack 630 wouldn't be a bad choice.

If the OEM fzj7x fusible links are not available but I still wanted an OEM link rather than a custom one, I'd find a 2-circuit one that is still being made by Toyota and that has a matching engine-side connector available. I can't think of one off the top of my head, but the 3-circuit hzj7x link is still available, as-is the matching engine side connector.

OEM is nice but this solution isn't waterproof so it'll eventually have corrosion if not greased.

Hello,

There are a few things to clarify.

1FZ engine fusible links are long gone. They are not available at the dealer, nor from other part suppliers. Perhaps there are some NOS 1FZ fusible links stashed somewhere.

Fusible links for the 1HZ engine are a direct replacement. They have the same connectors and bolt on to the 1FZ engine harness. Ask me how I know.

A while ago, in the Diesel/24 Volt section, I mentioned this issue. Namely, it was in a thread by Matt / @ToyotaMatt . We discussed this issue, and he designed and built a replacement part. Now it is available from his store.

If you are in need of 1FZ fusible links and you do not want to use the 1HZ part, get one from Matt / @ToyotaMatt . This may sound like a shameless plug, but it is the practical (and correct) thing to do.

1FZ engine fusible links have two wires:

1. One wire with an eye terminal.
2. One wire with a round connector.

Carbureted engines use one wire, namely the one with an eye terminal, which bolts on the black junction box. EFI engines use both wires.

The 1HZ fusible link has three wires, two of which have an eye terminal.

On a side note, an OEM negative terminal cable should have two wires. One grounds in the battery tray holder. The other grounds in either the front fender or the engine; I need to confirm where.

Hope this helps.





Juan

 

[TreadingLight]

That's good to know. Thanks for that. It looked like from the pics that the 1fz had a different connector from the 1hz but I must have mistaken that.

 

[ToyotaMatt]

DM coming later

That's good to know. Thanks for that. It looked like from the pics that the 1fz had a different connector from the 1hz but I must have mistaken that.

Hello,

There are a few things to clarify.

1FZ engine fusible links are long gone. They are not available at the dealer, nor from other part suppliers. Perhaps there are some NOS 1FZ fusible links stashed somewhere.

Fusible links for the 1HZ engine are a direct replacement. They have the same connectors and bolt on to the 1FZ engine harness. Ask me how I know.

A while ago, in the Diesel/24 Volt section, I mentioned this issue. Namely, it was in a thread by Matt / @ToyotaMatt . We discussed this issue, and he designed and built a replacement part. Now it is available from his store.

If you are in need of 1FZ fusible links and you do not want to use the 1HZ part, get one from Matt / @ToyotaMatt . This may sound like a shameless plug, but it is the practical (and correct) thing to do.

1FZ engine fusible links have two wires:

1. One wire with an eye terminal.
2. One wire with a round connector.

Carbureted engines use one wire, namely the one with an eye terminal, which bolts on the black junction box. EFI engines use both wires.

The 1HZ fusible link has three wires, two of which have an eye terminal.

On a side note, an OEM negative terminal cable should have two wires. One grounds in the battery tray holder. The other grounds in either the front fender or the engine; I need to confirm where.

Hope this helps.





Juan

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Below is the updated harness side connector plug & related parts contents being incorporated as a now main-stay to the 90982-08232 kit-form-kit

same goes for the 82627-60070 , 90982-08187 , 90982-08265 . i was able to source these additional kit parts in such a way with a larger overall electrical

parts supply order last month that adjusting any of the kits in yellow ink above current store page price is not necessary ..



as of now , only the 90982-08266 big grey ROBOT connector harness side parts would require that , so i chose to create a new stand alone listing , simply

using the same part# 90982-08266 for reference ...

as a general professionalism rule , i do not mix TECH. with this topic of $ , but i also think its important for fellow members to know these facts , because it was my goal here to keep things within reach

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[TreadingLight]

I see you have 90982-08232 but do you have 90982-08236? That's the link for my 90 hzj75 from Australia.

 

[ToyotaMatt]

Before we dive deep into the 90982-08236

can those who know & those who know more then those who know post any year and model land cruisers that uses these 2pin late 70’d - early 1980’s and beyond non-sealed type connectors

- I have noted they came in : Black Green
Grey ….

I have more then Fondly nicknamed these the ( LEGO-Era ) fusible links…


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[ToyotaMatt]

 

[ToyotaMatt]

 

[hino]

I too have a sketchy rig with no fusible links and trying to get back to reality and "close" to OEM
It's an '04 HZJ79

I have ordered:
Fusible Links, Blue/Glow/Ring, Black/AM1/Ring, Green?/Headlights/Plug
82627-60020
Junction Box, double pole:
82670-90K01

The EPC calls for junction box 82670-90K00 but this is only a single pole and doesn't match the fusible links
Found that GCC trucks have 82670-90K01, but the same fusible link so this must we what I'm after

Newer trucks come with fusible links 82627-60140 which has an extra white wire compared to 82627-60020

The harness side connector for the headlight plug on the fusible link seems NLA, I might just have to just replace with a 1 pole connector of some sort
@ToyotaMatt are you able to source this connector? I think it's the same as from this post:

70 series fusible link install?

Folks, I am in search of a photo, and possibly wiring description of installed fusible link PN 82627-60070. I’m not super smart on these, but am confident that I can follow directions. I am nearly certain the PO hacked out and replaced the fusible link on my FZJ70 with a piece of wire only...

forum.ih8mud.com

 

[ToyotaMatt]

I too have a sketchy rig with no fusible links and trying to get back to reality and "close" to OEM
It's an '04 HZJ79

I have ordered:
Fusible Links, Blue/Glow/Ring, Black/AM1/Ring, Green?/Headlights/Plug
82627-60020
Junction Box, double pole:
82670-90K01

The EPC calls for junction box 82670-90K00 but this is only a single pole and doesn't match the fusible links
Found that GCC trucks have 82670-90K01, but the same fusible link so this must we what I'm after

Newer trucks come with fusible links 82627-60140 which has an extra white wire compared to 82627-60020

The harness side connector for the headlight plug on the fusible link seems NLA, I might just have to just replace with a 1 pole connector of some sort
@ToyotaMatt are you able to source this connector? I think it's the same as from this post:

70 series fusible link install?

Folks, I am in search of a photo, and possibly wiring description of installed fusible link PN 82627-60070. I’m not super smart on these, but am confident that I can follow directions. I am nearly certain the PO hacked out and replaced the fusible link on my FZJ70 with a piece of wire only...

forum.ih8mud.com

i am both following you and also a bit lost on the : harness side connector for the headlight plug on the fusible link seems NLA, ?
are we talking a 2pin round o-ring sealed Male or Female connector w/ the BIG gauge / Larger terminals in both terminal bays ?
i am not so familiar with what your referring to as the Headlight-Plug here on your above very good technical description ,
fyi: that is NOT a white Fusible Links wire , it is OEM PINK .....
but , there is a White out there as well too ...Fyi

 

[hino]

@ToyotaMatt Ok no problem, this is fusible link 82627-60020:

And so I am looking for the harness side/truck side male connector for the circular 1-pole connector (which feeds the headlight circuit)
Believe it is 90980-10114 or repair wire 82998-12010

Let me know if this makes more sense lol and if you have options

 

[ToyotaMatt]

@ToyotaMatt Ok no problem, this is fusible link 82627-60020:
View attachment 3839519

And so I am looking for the harness side/truck side male connector for the circular 1-pole connector (which feeds the headlight circuit)
Believe it is 90980-10114 or repair wire 82998-12010
View attachment 3839531
View attachment 3839532
View attachment 3839530
Let me know if this makes more sense lol and if you have options

hummm......? ok ....

let me ask the needed tech. question another way here ....



- are we looking for the male / harness side round 1-pole connector plug that mates with the black female 1-pole connector plug on the fusible link above 8262-60020 ?


- or

- is this another female connector plug else-ware in your engine bay that you need its correct corresponding mating matching male 1-pole buddy ?


i ask this the way i do because your detailed EWD states : FL HEAD 0.5G

- also , that term ( Splash-Proof ) was a hold-over from a much older type of water-resistent connector ?


perhaps it's time for a nice detailed spread of photos below ?

we are already substituting a different main fusible links assy. here , and per your EWD. diagram , the FL HEAD 0.5G fusible link is the one i show below , ring terminal M8 on battery terminal , & smaller ring in a M5 / or M6 Junction box .....

i can't find any verifiable image of the actual 90980-11014 either ?

see .......

technical photos eliminate 98.6% of any speculation , and in a case where substitution parts are now involved , we can also conform and verify they will meet the correct fusible links needs and requirements of your Truck , especially the connection points Ring's and Connector plugs too

make sense ?

a few good photos up close and personal with what you have going on will set you up for success , especially when you went over the current state of our topic here and your good choice to bring things back to a original Toyota oem parts fit , form and function status ....


lets see this headlight circuit plug


- below is ( a ) 0.5G fusible link in it's stand-alone form :

 

[hino]

@ToyotaMatt appreciate the detailed responses! Currently the truck has no fusible links...just a red (headlight), white (AM1), and black (Glow plug) wires, plus starter wire, straight to the positive terminal. So I'm kind of flying blind reverse engineering from EWD and EPC

Truck is an '04 HZJ79 and using EWDs from here:

https://toyotamanuals.gitlab.io/RM0584E/htmlweb/rm0584e/contents/index3.html

And EPC from here:

https://toyota-general.epc-data.com/land_cruiser/hzj79l/8224/?

The EWD calls for a green 0.5g but in photos of the 82627-60020 it is in a protective sheath and can't confirm

- are we looking for the male / harness side round 1-pole connector plug that mates with the black female 1-pole connector plug on the fusible link above 8262-60020 ?

This statement follows what I'm looking for

i can't find any verifiable image of the actual 90980-11014 either ?

Part number typo - it is 90980-10114
I found a diagram of it buried in a Supra RM:
Page 246 of https://jeff.supramania.com/RM06H0E.pdf

I think I can see you have it in this from this thread:

The Diesel Tech / 24 volts FUSABLE Link / LINKS Topics Technical Resource & Discussion Thread Reproduction Applications 90982-08151 and Beyond ...

NO HIJACK Juan post photos please here ........ :) your welcome to Hello, Thank you for your patience. Pictures from PartSouq. This part is discontinued. Or so say the local parts guy and a couple vendors I have asked to. This is the fusible link for the 1HZ engine. After all...

forum.ih8mud.com

 

[ToyotaMatt]

@ToyotaMatt appreciate the detailed responses! Currently the truck has no fusible links...just a red (headlight), white (AM1), and black (Glow plug) wires, plus starter wire, straight to the positive terminal. So I'm kind of flying blind reverse engineering from EWD and EPC

Truck is an '04 HZJ79 and using EWDs from here:

https://toyotamanuals.gitlab.io/RM0584E/htmlweb/rm0584e/contents/index3.html

And EPC from here:

https://toyota-general.epc-data.com/land_cruiser/hzj79l/8224/?

The EWD calls for a green 0.5g but in photos of the 82627-60020 it is in a protective sheath and can't confirm
View attachment 3839707



This statement follows what I'm looking for


Part number typo - it is 90980-10114
I found a diagram of it buried in a Supra RM:
Page 246 of https://jeff.supramania.com/RM06H0E.pdf

I think I can see you have it in this from this thread:

The Diesel Tech / 24 volts FUSABLE Link / LINKS Topics Technical Resource & Discussion Thread Reproduction Applications 90982-08151 and Beyond ...

NO HIJACK Juan post photos please here ........ :) your welcome to Hello, Thank you for your patience. Pictures from PartSouq. This part is discontinued. Or so say the local parts guy and a couple vendors I have asked to. This is the fusible link for the 1HZ engine. After all...

forum.ih8mud.com

View attachment 3839722

ok ,

good discussion info above :

HOUSTON : The 82627-TEq-60020 has landed :


i see what i see peaking out , tell me what you see here below please :

if we both concur then it is

,

 

[ToyotaMatt]

Here is a interesting find at the bottom of my connectors gear box

This is the predecessor to the round water proof plug you have

This is same only a non-water proof older square connector housing same 3 links wires and the green one in the connector plug too

I like lost and found in my own gear boxes


And your male plug , seal and extra terminals in the bag ..

 

[hino]

@ToyotaMatt looks excellent! Do you have a link? Looking over your website for other possible goodies atm

 

[hino]

I received my fusible links 82627-60020
Can confirm green link on the circular connector
I'll update when I receive junction block 82670-90K01

 

[TreadingLight]

Well look at you with your fancy round sealed connector while some of us are slumming it with -08236 unsealed square connectors.