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 Post subject: Re: Turned a small problem into a disaster, melted alt wirin
PostPosted: Wed Jan 10, 2018 8:33 am 
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Location: White River in the Bush South Africa
Thanks for clearing up this "battery temp sensor" issue.....the KJ documention is not always properly updated so there is often a difference between the Theory of Operations and the wiring diagrams.

I checked the part numbers of the 05 and 06 USA CRDs and they are both: PN 56044672AA as is the 2005 Export CRD.
So no differences there and I have to accept that both USA models probably have the voltage regulators built into them.

Strangely the Export 2006 CRD has a totally different number of: 05142615AA so something changed then as regards the Export models but I will worry about that sometime in the future if an Export CRD owner posts a problem. :wink:


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 Post subject: Re: Turned a small problem into a disaster, melted alt wirin
PostPosted: Fri Jan 12, 2018 6:30 pm 
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BodhiBenz1987 wrote:
OK so nobody carries 8 gauge fusible link wire, other than one source on Amazon which only has 25 feet for $70+. Anyone know of a source I might be missing? I can always try to pull something from a junkyard but I'd rather use new wire if possible. Talked to NAPA and Advance and neither could source anything smaller than 12. Seems bizarre to me because the gas KJs used the same wire, so it's not like it's just the car being obscure.
Does anyone know whether there's any reason one of those big Maxi Fuses (or something along those lines) couldn't be used in place of the fusible link?


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 Post subject: Re: Turned a small problem into a disaster, melted alt wirin
PostPosted: Fri Jan 12, 2018 7:13 pm 
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joe_ wrote:
BodhiBenz1987 wrote:
OK so nobody carries 8 gauge fusible link wire, other than one source on Amazon which only has 25 feet for $70+. Anyone know of a source I might be missing? I can always try to pull something from a junkyard but I'd rather use new wire if possible. Talked to NAPA and Advance and neither could source anything smaller than 12. Seems bizarre to me because the gas KJs used the same wire, so it's not like it's just the car being obscure.
Does anyone know whether there's any reason one of those big Maxi Fuses (or something along those lines) couldn't be used in place of the fusible link?

I don’t see why not.
The fuse should be equivalent to the output of the alternator and the wire gauge should at least be the same.

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Bought my '05 CRD on June 2nd '07, used with 29,000 miles.
intake elbow and EGR delete. 7 volt Etecno glow plugs
Yeti stage 2 ECU tune. Straight pipe exhaust. DIY intercooler hoses
Provent and modified factory 180F thermostat
Replaced cylinder head (cracked) at 160,000 miles + ARP studs
2.5 inch lift, 255-75-17 tires.
Still love it.


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 Post subject: Re: Turned a small problem into a disaster, melted alt wirin
PostPosted: Fri Jan 12, 2018 9:14 pm 
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flash7210 wrote:
joe_ wrote:
BodhiBenz1987 wrote:
OK so nobody carries 8 gauge fusible link wire, other than one source on Amazon which only has 25 feet for $70+. Anyone know of a source I might be missing? I can always try to pull something from a junkyard but I'd rather use new wire if possible. Talked to NAPA and Advance and neither could source anything smaller than 12. Seems bizarre to me because the gas KJs used the same wire, so it's not like it's just the car being obscure.
Does anyone know whether there's any reason one of those big Maxi Fuses (or something along those lines) couldn't be used in place of the fusible link?

I don’t see why not.
The fuse should be equivalent to the output of the alternator and the wire gauge should at least be the same.

I totally agree; there are always different options to accomplish the same end results....it's called re-engineering! Do it all the time! :roll:

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 Post subject: Re: Turned a small problem into a disaster, melted alt wirin
PostPosted: Fri Jan 12, 2018 9:59 pm 
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You might want to try something along these lines

https://www.delcity.net/store/EATON-Mid!Range-Breakers-Switchable/p_823679.h_823680.r_IF1003?mkwid=s7VhDwgyD&crid=38094426869&mp_kw=&mp_mt=&gclid=CjwKCAiA1uHSBRBUEiwAkBCtzTLN48t3E5s3aO7ZMXqO-8GtflYGeoiZ4e0G36Rsz6yPkShOLOt1KBoC9u0QAvD_BwE

rather than a fuse. Get whatever amperage you want. It could save money in fuse replacements if it's something you're having trouble with.

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 Post subject: Re: Turned a small problem into a disaster, melted alt wirin
PostPosted: Sun Jan 14, 2018 10:08 pm 
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Update: I ended up taking the whole wiring harness, plus some 8-gauge fusible link, to a local battery specialist with a good reputation ... they also do wiring. They said it would be possible to do it with a Maxi fuse, and they can do it however a customer wants, but their preferred approach is to replicate the factory setup. So I opted for that. They actually had the fusible link in their shop, but by then I had already tracked some down online so they will use that, and also replace the rest of the alt wire. I should be able to pick it up tomorrow and hopefully everything else will be OK. Still nervous about any possible computer damage but nothing I can do but get it running and see. I could have done it myself but this way all the crimps will be done with the proper tool and I don't have to second guess myself, and can move on to whatever problems are there, or just figuring out the charging issue it had before I did this. 8)

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2005 Liberty CRD Limited, Light Khaki on Slate - 136,000 miles
1987 Mercedes-Benz 300D, Arctic White on Palomino - 314,000 miles
1978 Mercedes-Benz 240D 4spd, Lt. Ivory on Bamboo - 369,000 miles
2018 Chevy Cruze 1.6L turbodiesel, 6-speed manual, Satin Steel Metallic on Kalahari/Jet Black - 150 miles


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 Post subject: Re: Turned a small problem into a disaster, melted alt wirin
PostPosted: Tue Jan 16, 2018 7:44 pm 
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I put the harness back in the car, took the opportunity to clean up all the connectors, and so far, so good. It started easily and no lights or codes. I drove it on some errands today with no issues. I'm still concerned about whatever charging issue it had before, but it seems my stupid mistake did not cause any major problems at least. The shop did a nice job, replaced the whole alt wire with fusible link, connectors all neatly done ... saved me a lot of effort without the right crimping tools and whatnot.

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2005 Liberty CRD Limited, Light Khaki on Slate - 136,000 miles
1987 Mercedes-Benz 300D, Arctic White on Palomino - 314,000 miles
1978 Mercedes-Benz 240D 4spd, Lt. Ivory on Bamboo - 369,000 miles
2018 Chevy Cruze 1.6L turbodiesel, 6-speed manual, Satin Steel Metallic on Kalahari/Jet Black - 150 miles


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