FJ62 Fusible link wire gauges

[Coolerman]

Those that know me know that I own an FJ40. That means I know nothing about FJ62 wiring!
I have been asked to build fusible links for the FJ60/62.
I have found a source for the connectors/terminals in Japan, and have fusible link wire in 14,16,18 and 20 gauge.

What I need help with is what gauge fusible link wire to use for each link.

Here is what I do know, the FJ60 has three links on one three pin connector. Two green 20 ga and one red 18 ga. I even have the pin out and schematic for that.

What I don't know is the gauges for the FJ62.
There are 5 fusible links for a FJ62...
Fuel injection
Ignition x 2
Headlights
Alternator

If you have this information , or a link to it, please post it here.

Also does the year matter for these links? The one I'm wanting to build first is for a 1989 FJ62.

Once I build one and verify it, I will post them for sale on my web site. I will sell the full links, connectors/terminals for repair, and fusible link wire by the foot.
Thanks as always for sharing your knowledge...

Mark aka Coolerman

 

[LAMBCRUSHER]

in the FSM, they give metric specs for fuse link wire, which can be converted to us spec. I believe I use 16 guage wire and a weatherpac plug for my 88, on all but the alt circuit. I didn't have the right size fuse wire so I used #14 thhn...I have since added a #4 wire from alt to battery post without a link, in addition ton the factory wiring. between that and the headlight harness, the lights are great, and the volts don't drop...I know this didn't answer your question, but hopefully points you in the right direction...

 

[LAMBCRUSHER]

1.25B and .5g are 2 of the listed sizes I can find so far...the 1.25B is the alt circuit and the .5G is one of the ignitions...

 

[Coolerman]

Two down, three to go!

Ok, research shows the following data:
.5mm fusible link = 20ga fusible link
.85 mm fusible link = 18ga fusible link
1.0mm fusible link = 16ga fusible link
1.25mm fusible link = 16ga fusible link
2.0mm fusible link = 14 ga fusible link

Toyota must have had custom fusible link wire made as I have not found their exact sizes anywhere. The above are the closest equivalents.

 

[Spike Strip]

There are three fusible link wires, two green (0.5 sq. mm) and one red (0.85 sq. mm)

At least for FJ60s - Don't know if the FJ62 is the same.

I'd buy if you make new ones!

https://forum.ih8mud.com/threads/fusible-link-question.258630/

 

[jmstu76]

Bump for Mark

 

[Coolerman]

OK so does any one have a manual with schematics for a 1989 FJ62 they can share? I have spent a bit of time searching, but no joy. I have the 1985 Manual with schematics but I guess 85 FJ62 has the same setup as the FJ60.

Surely someone has this manual or could at least scan the pages?

 

[Spike Strip]

In my signature line is a download do fj62 FSM

 

[TrickyT]

OK so does any one have a manual with schematics for a 1989 FJ62 they can share? I have spent a bit of time searching, but no joy. I have the 1985 Manual with schematics but I guess 85 FJ62 has the same setup as the FJ60.

Surely someone has this manual or could at least scan the pages?

Mark,
Years for the FJ62, at least in the USA, were 1988-1990. The FJ62 is going to be different than the FJ60 because the '62 was EFI while the '60 was carburetor-ed, so ECU, electric fuel pump, injectors, bigger alternator, etc on the former. I have a FJ62 FSM and will look for the information you request later this evening.

 

[TrickyT]

Here's the page from the EWD showing fusible links and associated wire colors:

 

[Coolerman]

Here's the page from the EWD showing fusible links and associated wire colors:

TrickyT ... You da man!!!

 

[TrickyT]

No problemo. I used a bunch of your FJ40 connectors on a FJ40 re-wiring project I did with Cruiser Drew a couple years back and gotta say it would not have gone nearly as smoothly without the parts we got from you. So my hat is off to all the OEM style connectors and stuff you make available to the TLC community.

 

[jmstu76]

After a few weeks of trying to find a nice night to install what Coolerman built for me, it finally happened.

This is what I started with. This is by far the ugliest part of my imperfect cruiser

This is what Coolerman sent me. I was impressed to say the least. New waterproof connectors with the FL already attached with ring terminals crimped, soldiered and heat shrunk with a protective plastic coating.

He labeled the three connectors, One for the main, Alt and last EFI.

It made it a simple process to snip my mess and connect the pins he supplied in the kit to plug into the female end of the waterproof connector. I would have to say the most difficult part was getting the wire through the rubber ends on the connectors. Some Sylglide from NAPA made the job much easier.

I started with the main three wire FL

 

[jmstu76]

I then attached the pins for the connector

Then I pushed the pins into the female end of the connector. You get the idea. Pretty simple.

Connect the part Coolerman made and you are ready for the next wire.

 

[jmstu76]

Do these steps on the Alt white wire and then on the yellow EFI wire and you are starting to look good. Don't forget the new post for the Alt wire from BENO. YEAH ONUR!!!

In the end, you get to open your hood with pride because this is what your battery connections look like now

I give Coolerman serious props. He did an outstanding job on a project many people wanted nothing to do with. He gave me plenty of length on the FL to connect directly to the stock wiring harness without any cobbled connectors on my part. It is my understanding that Coolerman and I worked together on this prototype and if it went well, we may be offering this to the other FJ62 pilots in the same situation as I had. Feel free to look high and low for a better product (because I did) and no one would step up to help, either on Mud or the local Toyota Gurus in my neighborhood.

This is my report and I am one happy cruiser guy.

 

[red66toy]

That is fantastic! My FL wires have cracks in the insulation and I can see bare wires. I am definitely interested in this setup if more are made!

 

[Wallygator]

me too!

 

[Coolerman]

Wow! you would make a good PR man!

Awesome write-up and photos. Your help with this was the only way it got done!

Guys I'm working on making this a viable product. Right now I am swamped with making Fog Light harnesses and my day job... Keep checking my Web site. ASAP I will post fusible links for the FJ60 and FJ62...

 

[Trollhole]

Very cool. Perfect timing. Still cannot figure out why Toyota discontinued the 62 links but still has the 60. I'll be patiently waiting to stock my fuseable link drawer.

 

[Landpimp]

tons more 60's than 62's would be my guess

Nice work Coolerman!

Very cool. Perfect timing. Still cannot figure out why Toyota discontinued the 62 links but still has the 60. I'll be patiently waiting to stock my fuseable link drawer.