Isuzu Cars and Trucks 1981-1991

Fusible Links

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In addition to circuit breakers and fuses, the wiring harness incorporates fusible links to protect the wiring. Links are used rather than a fuse, in wiring circuits that are not normally fused, such as the ignition circuit. Isuzu fusible links are color coded and load circuits to match the color coding of the circuits they protect. Each link is four gauges smaller than the cable it protects, and is marked on the insulation with the gauge size because the insulation makes it appear heavier than it really is. The engine compartment wiring harness has several fusible links. The same size wire with a special hypalon insulation must be used when replacing a fusible link.

The links are located in the following areas:

RWD I-Mark



At the starter solenoid, red, 0.7
 
Between ignition switch and ignition coil, brown, 0.3
 

P'up



At the starter solenoid, red, 0.7
 

REPLACEMENT
  1. Determine which circuit is damaged, its location and the cause of the open fuse link. If the damaged fuse link is one of three fed by a common No. 10 or 12 gauge feed wire, determine the specific affected circuit.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Cut the damaged fuse link from the wiring harness and discard it. If the fuse link is one of three circuits fed by a single feed wire, cut it out of the harness at each splice end and discard it.
  6.  
  7. Identify and procure the proper fuse link and butt connectors for attaching the fuse link to the harness.
  8.  
  9. To repair any fuse link in a 3-link group with one feed:
  10.  
    1. After cutting the open link out of the harness, cut each of the remaining undamaged fuse links close to the feed wire weld.
    2.  
    3. Strip approximately 1 / 2 in. (13mm) of insulation from the detached ends of the two good fuse links, Then insert two wire ends into one end of a butt connector and carefully push one stripped end of the replacement fuse link into the same end of the butt connector and crimp all three firmly together.
    4.  



NOTE
Care must be taken when fitting the three fuse links into the butt connector as the internal diameter is a snug fit for three wires. Make sure to use a proper crimping tool. Pliers, side cutter, etc. will not apply the proper crimp to retain the wires and withstand a pull test.

  1. After crimping the butt connector to the three fuse links, cut the weld portion from the feed wire and strip approximately 1 / 2 in. (13mm) of insulation from the cut end. Insert the stripped end into the open end of the butt connector and crimp very firmly.
  2.  
  3. To attach the remaining end of the replacement fuse link, strip approximately 1 / 2 in. (13mm) of insulation from the wire end of the circuit from which the blown fuse link was removed, and firmly crimp a butt connector or equivalent to the stripped wire. Then, insert the end of the replacement link into the other end of the butt connector and crimp firmly.
  4.  
  5. Using rosin core solder with a consistency of 60 percent tin and 40 percent lead, solder the connectors and the wires at the repairs and insulate with electrical tape.
  6.  

  1. To replace any fuse link on a single circuit in a harness, cut out the damaged portion, strip approximately 1 / 2 in. (13mm) of insulation from the two wire ends and attach the appropriate replacement fuse link to the stripped wire ends with two proper size butt connectors. Solder the connectors and wires and insulate with tape.
  2.  
  3. To repair any fuse link which has an eyelet terminal on one end such as the charging circuit, cut off the open fuse link behind the weld, strip approximately 1 / 2 in. (13mm) of insulation from the cut end and attach the appropriate new eyelet fuse link to the cut stripped wire with an appropriate size butt connector. Solder the connectors and wires at the repair and insulate with tape.
  4.  
  5. Connect the negative battery cable to the battery and test the system for proper operation.
  6.  


NOTE
Do not mistake a resistor wire for a fuse link. The resistor wire is generally longer and has print stating, "Resistor-don't cut or splice".

When attaching a single No. 16, 17, 18 or 20 gauge fuse link to a heavy gauge wire, always double the stripped wire end of the fuse link before inserting and crimping it into the butt connector for positive wire retention.



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Fig. Fusible link FWD I-Mark non-turbo and Trooper



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Fig. Fusible link FWD I-Mark DOHC and Turbo



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Fig. Fusible link RWD Impulse



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Fig. Fusible link FWD Impulse



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Fig. Fusible link Stylus



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Fig. New fusible links are spliced to the wire

 
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