Ford Escort/Lynx 1981-1990 Repair Guide

Fusible Link


Fusible links are short lengths of special, Hypalon (high temperature) insulated wire, integral with the engine compartment wiring harness; they should not be confused with standard wire. A fusible link is several wire gauges smaller than the circuit which it protects. Under no circumstances should a fusible link replacement repair be made using a length of standard wire cut from bulk stock or from another wiring harness.

Fusible links are used to prevent major wire harness damage in the event of a short circuit or an overload condition in the wiring circuits that are normally not fused, due to carrying high amperage loads or because of their locations within the wiring harness. Each fusible link is of a fixed value for a specific electrical load and should a fusible link fail, the cause of the failure must be determine and repaired prior to installing a new fusible link of the same value. The following is a listing of fusible links wire gauges and their locations:

The color coding of replacement fusible links may vary from the production color coding that is outlined in the text that follows.

Green 14 Gauge Wire-on vehicles equipped with diesel engine, have two fusible links located in the glow plug wiring to protect the glow plug control.
Black 16 Gauge Wire-one fusible link located in the wiring for the rear window defogger.
Red 18 Gauge wire-vehicles equipped with diesel engines use one fusible link located in the heater fan wiring to protect the heater fan motor circuit.
Brown 18 Gauge Wire-one fusible link is used to protect the heater fan motor circuit.
Blue 20 Gauge Wire-vehicles equipped with gasoline engines use two fusible links in the wire between the starter relay and the EFE heater. On 1988-90 vehicles, a fusible link is installed in the engine compartment near the starter relay and protects the passive restraint module circuit. Vehicles equipped with diesel engine, uses one fusible link to protect the vacuum pump circuit.

Always disconnect the negative battery cable before servicing the vehicle's electrical system.