Thanks, Stuart.  I am still learning my way around the wiring diagrams in the Bentley.

I agree, most fusible links are hard to replace - but Nissan, back when they were Datsun, used some that were easily replaced - practically fuses - right up by the battery.  I know because I had one that controlled the lighting circuits blow due to corrosion further the wiring in an old Datsun 210 - a Datsun mechanic showed me how to change it, a less then 5 minute job.  Not a fuse, but not bad.

For the Vanagon, I'll look to high amp fuses (or circuit breakers?) in a few useful places.  For these ideas, I am grateful to the whole crew on this list - you have both educated and empowered me.

James
Ottawa, ON
'91 Orly Blue Westy Weekender

> Date: Thu, 11 Feb 2016 18:03:25 -0800
> From: stuartmacm@GMAIL.COM
> Subject: Re: PS pump switch, engine compartment wiring harness, ECU,              starter
> To: vanagon@GERRY.VANAGON.COM
> 
> Bentley doesn't show any I can find.
> 
> They are a fail-safe for preventing a major fire caused by a short in big
> wire.  Those big unfused wires don't melt down until everything else has.
> 
> They are not easily replaced (especially by the side of the road), so
> putting an appropriately sized fuse in these unfused power supply lines is a
> better idea.
> 
> Stuart
> 
> -----Original Message-----
> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
> James
> Sent: Thursday, February 11, 2016 2:46 PM
> To: vanagon@GERRY.VANAGON.COM
> Subject: Re: PS pump switch, engine compartment wiring harness, ECU, starter
> 
> And VW were not averse to fusible links - I've had them fail or known of
> failures of fusible links in other VWs, Golfs, Rabbits.  One was on a Golf
> III starter - went up in a little poof of smoke!
> 
> Are there many (or any) of these on the Vanagon?  In places, it's as if VW
> were depending on using low gauge wire to limit the damage in the case of
> short circuits.
> 
> James
> Ottawa, ON
> 
> > Date: Wed, 10 Feb 2016 20:41:13 -0500
> > From: d23haynes57@HOTMAIL.COM
> > Subject: Re: PS pump switch, engine compartment wiring harness, ECU,
> starter
> > To: vanagon@GERRY.VANAGON.COM
> >
> > There are many wires and even components on the vanagon that are not
> protected from over current or shorted circuits. From the factory the
> connections to the power steering pressure switch were in an insulated
> cover. Over time both from age and heat along with mechanic abuse the covers
> crack and fall off or get knocked open and lost from work in the area. The
> connectors can also loosen over time. When the pump or line gets serviced
> the pipe may even get relocated so that these now open connections come into
> contact with other metal objects. The real problem here was lack of care and
> maintenance. That is if this was the real problem. Amongst things not fused
> you have the ignition coil, injectors, fuel pump, O2 sensor heater, and all
> that wiring from the battery and alternator through so many switches with
> fuses between the switches and the component being protected. Think of your
> house not having fuses or circuit breakers in the source panel but rather
> between the switch and the appliance. Point is this one fuse addition is
> sort of like a band aid when what was really needed is good competent work
> to not have created the condition in the first place. The details matter.
> >
> > One option for mass system protection is to use fusible links. Special
> wire designed to burn out during large overload conditions. Usually you size
> these one size smaller than the wire being protected. Any old school GM
> mechanic knows about these very well.
> >
> > Dennis
> >
> >
> >
> > -----Original Message-----
> > From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
> John Rodgers
> > Sent: Tuesday, February 9, 2016 11:03 PM
> > To: vanagon@GERRY.VANAGON.COM
> > Subject: PS pump switch, engine compartment wiring harness, ECU, starter
> >
> > This is kinda to bring everyone up to speed on  recent problems on my '88
> GL Vanagon.
> >
> > A little while back driving down the road the starter suddenly engaged.
> > Stalled the engine. Clutched it, but could not turn off the starter.
> Fnally did, and long story short, got it tow to HESCO, one of the best
> garages in the area. They will work on anything. Even had a snowmachine
> mounted on wheels in there.
> >
> > Anyway, after checking, they found the engine bay harness was fried, as
> was the ECU and the starter. It seemed the meltdown began with a PS switch
> wire.
> >
> > What has been learned from knowlegable folks ln this list, is that:
> >
> > 1) The PS steering switch circuit is a hot, un-fused circuit. There is no
> protection of this circuit on these vans.
> >
> > 2) The fix ( by way of David Beierl) is to install  a 7.5 amp fuse in the
> engine wiring box, in the red wire that goes from the B+ post inside the box
> to the relay box.  That will keep your harness from smoking.
> >
> > 3) A thru 2003 BRAND NEW FROM THE FACTORY starter for a TDI DIESEL, fitted
> with an adapter plate, works perfect. This also works with a Subaru engine
> conversion.
> >
> > See following links:
> >
> >
> http://www.ebay.com/itm/100-NEW-STARTER-FOR-VW-DIESEL-TDI-MANUAL-TRANS-HIGH-
> TORQUE-2Kw-ONE-YR-WARRANTY-/300475513229?hash=item45f5bc798d:g:p8EAAOxyJX1TF
> mlY&vxp=mtr
> >
> > http://www.westyventures.com/parts.html
> >
> > Necessary pigtail:
> >
> > http://www.thesamba.com/vw/classifieds/detail.php?id=1673971
> >
> > Kudos go to Peter Jones at Van Cafe for scaring me up an ECU with the
> pigtail already installed formy SHOEBOX ECU MONITOR. Since my stroke I don't
> have fin enough muslce control to do that fine soldering required.
> > Hand shakes just a little to much. But he got'ter done. He is also going
> to put Davids fix on the Van Cafe  web site next to the PS swich info.
> >
> > And KUDOS to JAY BROWN for his advice on the starter pigtail and sending
> me a new starter relay to replace the one that got fried in all this. I
> happen to have his headlight relay set-up in both my vans, too.
> >
> > There were many others who provided input on this, and I want to thank you
> all too.
> >
> > I seriously hope this helps someone else avoid the problems and expense
> that I have had with this.  Remember, fore warned is fore armed! Fuse that
> wire and avoid all this some place on a dark and stormy night, between
> Somewheresville and Nowheresville!
> >
> > John
>                                           =