Real Time Help Please EFI Fuse....

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May 30, 2005
For those who didn't see it - I had a EFI fuse melt down earlier this week.

Moved the charcoal canister to flip the fuse box over to inspect an hour ago and I'm not having good results.

Cleaned top area of fuse socket with dremel hoping to pull it down and out, but it was melted to the plastic and it broke of the whole thing when I tried to pull it.

I can't see any other areas of overheating on this circuit from the feed side. The bare wires are from where I cracked off the insulation trying to pull the fuse socket.

Anybody have any quick advice on where to go from here?

As you can see from the pics the replacement fuse was starting to melt down on the same side as the one that totally melted down. Another shows the heat effects of the EFI fuse socket from the top. The other shows the socket in the broken off plastic housing.

I'm thinking I'll cut the socket out, replace it and try to super glue the plastic fixture back into place in the fuse box, then see what happens.

Opinions help please. I'm gonna give it about an half an hour before I do something.

Fuse Block.jpg
Fuse Comparison.jpg
Fuse Block Top.jpg
The fix is simple. You can either attempt to clean up your existing metal contact and repair the insulation on the wire with tape, heat shrink, etc, or you can get a replacement from Toyota (special order). Then remove the other contact and reinstall both contacts in another existing empty position in the fuse box.

I have previously added two additional fused circuits using empty slots. There are GM replacement fuse contacts (available in auto parts stores) that can be modified to go into the Toyota fuse block. A triangular hole needs to be drilled / filed in the side, and the portion that clamps the wire needs to be rearranged. Would be much simpler for you to get the Toyota replacement contact.

Regarding removing the contacts: They are pinned in place by a plastic clip that needs to be levered out of the way with a very small, flat bladed, jeweler's screwdriver.
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Duh.....thanks Rich....

I just walked in from the garage and I'm thinking - why try to glue anything - I have four empty slots right next to this thing. I'm just in idiot mode right now.

I've got jeweler's screw driver and lot's of little ones that I use for gunsmithing. Which side are the clips on - I'm old and I can't see s%*t anymore?

I've got the funked up one clean as a whistle, taped up and ready to go.

The end question will be - what's sending the heat to this circuit?
Look at the contact that you cleaned up. There is a hole in the side. The plastic finger, which is part of the fuse box assembly, wedges into that hole. Look inside an empty slot with no fuse contacts. Use a flashlight. You will be able to see the finger and then you should be able to understand how it needs to be wedged out of the way to permit removal of the other contact. Use one screwdriver to get the clip out of the way, and another to push down on the contact.

Corroded contacts result in a high resistence connection to the fuse. Current flow across the resistence results in heat.
Use a tool like this.....

I'll get my glasses out now. It really s78k's gettin old. LOL

Thanks Rich.
Works like a gem - I'm on my way to making the wifey very happy. I make her happy. She make's me happy. lol

Had to cut the melted one off with dremel, but the feed side popped right out with jeweler's tool.

TX again Rich - kudos....

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