I got lost ..
At least one of the wires must have been interrupted, causing the headlight circuit to fail.
With your repair, you must have either removed or bypassed that interrupted piece of wire. So, were was the interruption?
I guess, there are two possibilities now, concerning the leftover 'wire' :
a) It was never a fusible link, but just anything wire a PO put.
b) It actually was a fusible link, which blew somewhere on a section you removed or bypassed, and you are now running on the remaining leftover shorter part of it.
For a): Wouldn't make much of a difference to the previous condition, but would be quite dangerous.
For b): It would still be a fuse, but a much weaker and unpredictable one, as the previous shortage heated the entire fusable link. It blew at the weakest point, but the rest would also be compromised.
I wouldn't guess. In any case: Replacement is needed; soon.
Try to find the original join to the original harness (plug&socket and bolted ring terminal) and go from there. Crimp a ring or rewire the existing plug. Put new midi fuses of the ampere ratings that are suggested by the original fusible links color. Actual fusible links would be best, but you can also use slow MIDI fuses. It's only important that the unprotected distance between battery terminal and fuse is as short as possible and well insulated.
You may find something like this: MIDI fuses holder that directly connects to the battery terminal:
MTA MidiVAL Sicherungsverteiler 3-fach SX MIDI BF1 Streifen Sicherung 32V Halter | eBay.de - https://www.ebay.de/itm/184878424937?mkcid=16&mkevt=1&mkrid=707-127634-2357-0&ssspo=uipxyurutrc&sssrc=2349624&ssuid=urJMHgV8Twi&var=&widget_ver=artemis&media=COPY.
Not original, but safe.
Those Napa fusible links have one issue: You don't know the correct rating you need, as the concepts are different:
- Toyota goes by amperage (just defined a bit clumsy by square x length, but actually quite straightforward due to the color code).
- Napa / US concept goes by gauge rating: The fusible link of choice is one gauge level smaller than the average gauge of the circuit to protect. But you don't know the average gauge of the Toyota's circuit (which is a statistical value, not the actual wire gauge of the harness, as chassi rails and other components play in).
Good Luck Ralf
