Subject: Howto-> Electrical: Fusible link Author: shogun (moderator) : member since March, 2004 : 16322 posts Posted on: 2011-12-16 20:05:19

This is an article about the fusible link - it's symptoms and renewal.

PROBLEM:
The fusible link is a protective device that will prevent a burnout in wiring due to a short circuit or an electrical fire due to the same thing.

The problem is that as with all fuses - the fuse is a piece of resistive wire. This means that as current flows through it, it will heat up and cool during use. As it's effectively a piece of metal trapped between two bolts, it'll flex every time, and eventually metal fatigue will get the better of it.

WHEN TO DO THIS JOB:
-When the existing fuse fails
-If your current fuse has more than 100k miles on it
Personally, I would change this as a matter of cause on any vehicle with 100k miles or more on it - it's a part worth a few pennies that will cause you a very large headache if it fails while you're out and about.

SYMPTOMS:
Everything electrical on the car dies, with the exception of:
Engine
Gearbox
Headlights
Indicators

It's extremely weird driving the car around with no guages...

This is the offending part:

http://i11.photobucket.com/albums/a190/Ferret101/57d661e4.jpg
FIX:

You need a new fusible link, you'll need to order one from the dealer but they only clock to about 40 pence if you have the basic 80 amp version.

Firstly, disconnect battery or batteries please, we're going to be working with unfused battery lines in close proximity to bodywork...

http://i11.photobucket.com/albums/a190/Ferret101/8499ffda.jpg
best place to isolate is the earth point in the left of the boot near the taillight cluster. Wrap something around the ends of the leads so they cant move and recreate a circuit.

On the v12, the link is in a plastic case just in front of the right battery, you can see it here in the bottom of this image:

http://i11.photobucket.com/albums/a190/Ferret101/35226e71.jpg
You'll need a 10mm spanner, open the case and you should see the broken link with two bolts, partially unwind the two bolts and you should be able to lift the remenants out of the holder:

http://i11.photobucket.com/albums/a190/Ferret101/1a304582.jpg
Offending item and new item:

http://i11.photobucket.com/albums/a190/Ferret101/b3ad3d78.jpg
Drop the new link into these bolts and carefully tighten them up - they need to be tight but don't overdo it - the fuse is made of soft material and could easily be broken by the bolts, it should now look nice and clean:

http://i11.photobucket.com/albums/a190/Ferret101/b97be4b2.jpg
That's it! clip the plastic case back together, reconnect your earthing point and enjoy another 100k miles

text and pics by Ferret101,'91 850Ci Auto, U.K. version
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additional comment from my side: there are 2 of these fusible links, each battery has one as far as I remember.

E32:750iL 11/88,750iL Highline 03/90,02/98 E36 M3
SHOGUN'S TRICKS AND TIPS FOR THE SEVEN SERIES

• Howto-> Electrical: Fusible link (url) - shogun 2011-12-16 20:05:19 (260 views)