Hi, On a 96 5.9 CTD, what have worked to replace the fusible link for the relay for the intake heater? I know they pull about 175 or so amps each when on. Any ideas for a fuse or link? I would imagine most have hardwired them with a smaller Gage wire to act like a fusible link? Thanks for what input I receive, Artie

 

Most any autoparts has fusible links. Don't recall what the grid link is but the color of the wire indicates the amperage

 

I may be way off here, but I don't think there is a fusible link in the heater grid system. One small wire to the relay is always hot, the PCM provides a ground and the big black load carrying wires go straight to the heaters. I bypassed the PCM on mine and have a toggle switch for ground so I can cycle them manually.

 

There is direct from the battery to the hot big stud of the Grid Heater solenoids.

I cannot find a Chrysler part number separate from the main harness though.

 

Looks like 12gauge fusible link:

 

Thanks for the replies. I had a factory recon motor from Cummings that didn't have a insulating washer on one of the grids terminal, and when the relay energized, it took out one fusable link, and the other was hardwired with a 4" piece of 10 GA. I'm thinking of using a similar 4" piece of 10 or 16 GA, the original looks to be 12 GA, to act like a link. I don't know who makes a regular fuse that can handle 200a, which is what 1 grid heater pulls. Any tricks to replace the manifold gasket? I removed the first 4 lines and got the plate out. Wondering how to loosen the fuel filter a tad to slide the cover and gasket in? Any ideas? Thanks, Artie

 

You can get large fuses from places like waytekwire.com and others, however the purpose of a fusible link is to allow a very short burst of over teh max amperage... where a normal fuse would blow the fusible link will hold for a sec to allow the current draw to settle

 

bnold,
That's almost the same as the diagram in my 97 manual, but it doesn't have fusible link printed. It does show the 12 gauge wire connected to 6 gauge, so I'm pen & inking it in.

Thanks for the info.