Chrysler Repair: engine compartment fusible link blowing94 minivan, chrysler town and country minivan, chrysler town and country

Question
QUESTION: Hi, I have a 1994 Chrysler Town and Country minivan with 185000 miles on it.  A couple of weeks ago the whole van went dead and didn't start. dead silence.  We found out the 40 amp fusible link in the engine compartment was blown. This one controls the electric windows and ignition I believe.  The mechanic checked out the van and said the electric fuel pump was pulling too much current and needed to be replaced. We did and a couple of weeks later the fusible link blew again. Any ideas where to start checking for excessive current draw on the system? thanks Gary

ANSWER: Hi Gary,
Can you tell me the color of the insulation on the fusible that is blowing? There are two fusibles in series that power the circuit breaker that powers the windows. I have the '93 wiring diagrams (which appears to apply to the '94 model) so I should be able to give you some help
Roland
PS Use the "thank/rate" tab below to get back to me without having to wait for me to be available to take a question.

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QUESTION: Hi, thanks for the quick answer, the color is green and I believe it's the second one down from the top of the fuse block. There are two green fuses together and it's the second one I think. thanks Gary

ANSWER: Hi Gary,
Maybe I need the '94 manual because the '93 shows there to be 7 fusible links from the battery to the fuses and none are green. In fact in the overall chart there are no fusible link sizes that are green. Interesting too is that Chrysler doesn't give an amp rating for fusible links, rather wire gauge sizes only. There is however one dark green 'hypalon wire fusible link' that is associated with the alterator output wire. No other green links that I can see. Just in case, which engine do you have as their charging systems differ?
Do you perhaps mean a fuse? Although in the '95 underhood box there are no fuses so large as 40 amp either. So let's try it again. If there is a fuse box under the hood then I suspect it should not have fusible links in it at all. Can you describe the layout of the box? Are there any numbers or a name associated with the fuse/fusible link which is blowing?
Roland

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QUESTION: Hi, sorry about the confusion, the box is on the drivers side above the battery, at the top left there are a bunch of regular blade fuses under those fuses are 6 or 7 black relays on the left side at the top of the box is a black starter relay or so it says, on the right side there is 5 or 6 fusible links of different amps then beneath those links are a few more relays. if you want I could take a picture of it? Gary

Answer
Hi Gary,
The '95 diagram doesn't have any fusible links in the box, and  except the external dark green one that is evidently the generator output circuit, which makes sense since that should be dealing with maybe 100 amps or more. That under hoodbox is horizontal in layout, so again this may be a different schematic situation than in your '94.
If your fusible is blown again, maybe you can survey all the fuses and find out which circuits are dead (test with the ignition switch in the run position). Once you know that, maybe we can figure out how to determine which fuse(s) are overdrawing the fusible link. Thanks for the photo offer if you can send it without hassle.
Roland


Hi Gary,
Send the photo to rfinston@hotmail.com
If you can describe what are the wires to which each end is soldered that would help to identify where it is in the circuit diagram.
Thanks for the evaluation and nomination.
Roland

Hi Gary,
The photo is identical to the layout in the '95 manual which is what I thought. But, I can't identify which of the "fusible links" on that right side is blowing. They are shown as fuses in the wiring diagram, not fusible links (which are actually long pieces of wire covered with insulation, thus my confusion in terminology with you). The manual says that the first 5 fuses are 40 amp and the very rearmost one is 30 amp. Is that correct? And then which is the one that is blowing, counting as #1 the front-most fuse? What does the box lid say the fuse that is blowing does? If the lid does describe the purpose of those fuses, please tell me in order what they do, from front to back? They may have been rearranged between what you have and what the '95 manual shows them to be for.
Roland