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Discussion Starter #1
Hi, does anyone have any experience of what I think is a fusible link cable spliced into the starter motor cable breaking or what looks like been rubbed away then melted.

It's located below the bell housing and attached to a mounting bracket along with 3 or 4 other connectors which appear to go to sensors on the exhaust system.

This was only spotted when I removed the covers underneath trying to locate a problem with the alternator not charging and a long cranking time before the engine would fire up I decided to investigate.

I suspect this has something to do with the alternator fault and that the glow plugs are not working either.

I would attempt to repair the cable but feel it is beyond the scope of a domestic soldering iron and that the original splice was covered with specialist sleeving.

Question is can this section of harness be purchased as a replacement part and more importantly why it happened in the first place.

Any advice would be appreciated.
 

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Where does the cable go? There's a known problem on the starter motor exciter wire where the terminal and wiring rots/corrodes then your car won't start intermittently. Usual fix for that is to replace the cable/terminal

Wasn't aware there was a fuseable link in the wiring down there

Any chance of posting a photo?
 

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Discussion Starter #3
I have taken a few photos, will try to download them and see if they come uo in the thread.

I had the intermittent starting with the exciter wire previously and replaced the terminal with no further problems. this one is the heavy duty cable (brown/red) that bolts onto the starter. The splice is about 12" below that connection and coloured red, running between the cross member and anti roll bar across to the offside of the engine heading up towards the alternator. Haven't sussed out exactly where yet but I will find out tomorrow.

I have a copy of the glow plug circuit and it shows two fusible link wires connected to what they call the generator.

I will have a go at the photos shortly but thank you so meanwhile for the reply.
 

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If you think the alternator is faulty - and it may well be, as these alternators have a poor track record, you need to do some voltage checks using the EVIC hidden menu. Before cranking you should see 12.6V with a fully charged battery on light load. When cranking, volts may drop as low as 9V in cold weather. With engine running, volts should be about 14.4V if alternator OK. Have you had the battery/alternator warning lamp come on with the engine running? If so, you will also have a couple of stored DTCs. I think the heavy duty cable from battery to starter relay contains the fusible link and is also connected to the alternator output.
 

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Discussion Starter #6
Thanks Dvc,
Evic showed 11.9 volts before start up dropped to 10.8 during cranking then back to 11.8 once started, no increase at any revs. Battery light on dash display so no output from alternator. Hoping its something to do with this broken cable.

Only code was open circuit on glow plug.
 

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Discussion Starter #8
Took some pics today at a reduced resolution but still unable to attach to message, apparently too large (max of 195KB allowed). ??

However I have been searching the extremely comprehensive forums and found a previous thread from 22/07/2013 by TRUCRZ in the UK and Europe Forum which is suspiciously like the problem I have and with a clear picture, also a TSB link for Jeep posted by [email protected] on the same thread.

I would love to add a link here but don't have the knowledge.

Trucrz was lucky in spotting a spark emitted from the rubbed cable whereas mine had completely melted through and think I have been very lucky not having had an engine bay fire. I've already lost a 300crd a year ago through immersion in a river, losing another to fire would have been a bit ironic !

I digress, having seen many threads about the wires running beside the aircon pipes and possible contact wear I think the possibility of a short on the starter cable carrying a permanent live supply is potentially fatal for the car and should be inspected at the earliest opportunity.
 

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Discussion Starter #9
Thanks for the diagram Dmc, if I'm not mistaken you also posted a reply in the previously mentioned thread just to jog your memory.

Cheers
Dave
 

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Discussion Starter #11
Finally got some pics at the correct resolution (thanks Theone300).

Pulled the alternator loom out of the engine bay which wasn't a simple operation and ordered a new one off fleabay. Should be fun refitting the new one I'm sure.

I was going to attempt removing the alternator to check it but to be honest I can hardly see it never mind reaching bolts etc. hopefully it hasn't burnt itself out.

Respect to those members who have successfully removed the unit from the front or rear, I just can't see how they managed.

As the glow plug module is a direct connection to the alternator output hopefully that too is ok unless someone knows how to check it off the vehicle.
 

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The "official" method of removing the alternator from the rear involves lifting the engine off its mounts and is labour intensive. The "unofficial" method (thanks to UKChrysler300C) allows removal from the front and is much quicker - see attachment, which also includes comments from another member.
 

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Discussion Starter #14
That's exactly it Simon, thanks for posting the TSB pdf link once again. (much clearer pic than mine)

Other members please have a look and check your own car. Mine has only done 35K so it is worthwhile having a look at yours now and again. Can have quite serious consequences if missed.
 

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That's exactly it Simon, thanks for posting the TSB pdf link once again. (much clearer pic than mine)

Other members please have a look and check your own car. Mine has only done 35K so it is worthwhile having a look at yours now and again. Can have quite serious consequences if missed.
It certainly can, I have seen a facebook members car caught fire and was destroyed because of it.
 

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Discussion Starter #16
Where does the cable go? There's a known problem on the starter motor exciter wire where the terminal and wiring rots/corrodes then your car won't start intermittently. Usual fix for that is to replace the cable/terminal

Wasn't aware there was a fuseable link in the wiring down there

Any chance of posting a photo?
New alternator wiring loom arrived and I have attached a couple of photos to show where the fusible links are located.

The one that went on mine was the light blue coloured one (8GA) positioned about 6 o'clock on pic 1 which is 14" from the starter motor connection.

The second is the green one (10GA) positioned about 3 o'clock spliced to the connector which fits into the loom at the drivers side suspension turret.

The third is the black one (12GA) about centre of the pic. crimped directly to alternator output which then goes to the glow plug module connector.

Also included a pic. of the part number should anyone be unfortunate enough to need it !
 

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Discussion Starter #17
Just to close down the post, thank you to the members who helped and I am happy to say that the replacement loom is now installed and fortunately no damage to the glow plug module or indeed the alternator although I did take the opportunity to replace the glow plugs and fit a splash shield at the same time.

Happy bunny once again !
 
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