Fusible Link Wire Gauge

[jrobie79]

anyone know what size the fusible link wire is? I might have accidentally cut it too short installing new battery terminals.

What is the suggested method for connecting the existing fusible link wire to the new? Crimp (butt) connectors?

[bmwman91]

A 6mm^2 wire is about equivalent to 9ga wire, so I guess that leaves 8ga as the nearest thick-enough common gauge available. You can use but splices, but you will really want to be using either a good ratcheting crimper or a high-leverage dual action type. Poorly made crimps are...undesirable. The wire with the fusible link powers the Motronic unit, fuel pump and injectors. It is super annoying when the connection starts getting intermittent (guess how I know!).

I am not sure if you bought wire yet, but this stuff is probably pretty close to what is in the factory setup (Waytek is where I get all of my wire harness materials, I have no affiliation).

https://www.waytekwire.com/item/WL8-0/8GA-GXL-Black-Automotive-Wire/

This is a legit way to join the wires:

https://www.waytekwire.com/item/33980/Molex-19164-0079-Perma-Seal-Butt-Connector-/

And if you want to buy the last set of butt splice crimpers you will ever need:

https://www.waytekwire.com/item/480/Hand-Ratchet-Crimp-Tool-22-8-AWG/

[jrobie79]

A 6mm^2 wire is about equivalent to 9ga wire, so I guess that leaves 8ga as the nearest thick-enough common gauge available. You can use but splices, but you will really want to be using either a good ratcheting crimper or a high-leverage dual action type. Poorly made crimps are...undesirable. The wire with the fusible link powers the Motronic unit, fuel pump and injectors. It is super annoying when the connection starts getting intermittent (guess how I know!).

I am not sure if you bought wire yet, but this stuff is probably pretty close to what is in the factory setup (Waytek is where I get all of my wire harness materials, I have no affiliation).

https://www.waytekwire.com/item/WL8-0/8GA-GXL-Black-Automotive-Wire/

This is a legit way to join the wires:

https://www.waytekwire.com/item/33980/Molex-19164-0079-Perma-Seal-Butt-Connector-/

And if you want to buy the last set of butt splice crimpers you will ever need:
https://www.waytekwire.com/item/480/...Tool-22-8-AWG/

awesome, exactly what I was looking for