Electrical 1990 - Blue Fusible link burning up when key is turned to on after HCI swap

Ragtop50

Member
May 31, 2017
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I have a 1990 LX convertible that I just completed doing a H/C/I swap on. I got everything back together and now when I turn the key to on (but not cranking the engine), the blue 20 ga fusible link that comes from the starter solenoid burns up. It appears to be fine with the 12 volts to it with the key off. I replaced it with a fuse to test and I am getting the same thing, blows the fuse as soon as the key is turned to on. It worked fine about two weeks ago when I turned the key on a few times to prime the fuel lines and check for leaks around the regulator, injectors and fuel rails while I had easy access to them. Since then I have installed the upper intake (GT40 tubular) as well as all of the accessories, MAF, exhaust, etc.
Now it is burning up the fuse link. It must be a pinched wire, but with this information, where should I start to try and trace and find the issue? My wiring harness is in good shape, so I don't really expect an age issue from brittle wires.
I have some wiring diagrams I can use as well, and it looks like when this link burns up it kills power to the EEC relay?

I appreciate any input and advice on the best way to track down this issue.

BTW, I am running an A9P with a Quarterhorse. I do have another working A9P on hand as well.
 
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The following are diagrams courtesy of Tmoss & Stang&2birds

Fuel, alternator, A/C and ignition wiring
fuel-alt-links-ign-ac.gif


A short circuit in the red wires on the diagram would be the first area to look at.
The fuel injector power or fuel canister purge valve would be a good place to start.

See the following website for some help from Tmoss (diagram designer) & Stang&2Birds (website host) for help on 88-95 wiring; http://www.veryuseful.com/mustang/tech/engine/ Everyone should bookmark this site.[/b]

TFI module wiring for 94-95 Mustang GT
http://www.veryuseful.com/mustang/tech/engine/images/Mustang-94-95-IgnitionControlModule.gif

Complete computer, actuator & sensor wiring diagram for 94-95 Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/94-95_5.0_EEC_Wiring_Diagram.gif

Complete computer, actuator & sensor wiring diagram for 91-93 Mass Air Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/91-93_5.0_EEC_Wiring_Diagram.gif

Complete computer, actuator & sensor wiring diagram for 88-90 Mass Air Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/88-91_5.0_EEC_Wiring_Diagram.gif

Ignition switch wiring
http://www.veryuseful.com/mustang/tech/engine/images/IgnitionSwitchWiring.gif

Fuel, alternator, A/C and ignition wiring
http://www.veryuseful.com/mustang/tech/engine/images/fuel-alt-links-ign-ac.gif

O2 sensor wiring harness
http://www.veryuseful.com/mustang/tech/engine/images/mustangO2Harness.gif

Vacuum diagram 89-93 Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/mustangFoxFordVacuumDiagram.jpg

HVAC vacuum diagram
http://www.veryuseful.com/mustang/tech/engine/images/Mustang_AC_heat_vacuum_controls.gif

TFI module differences & pin out
http://www.veryuseful.com/mustang/tech/engine/images/TFI_5.0_comparison.gif

Fuse box layout
http://www.veryuseful.com/mustang/tech/engine/images/MustangFuseBox.gif

Mustang 5.0 Lights and Radio schematic, by TMoss:
http://www.veryuseful.com/mustang/tech/engine/images/mustangFoxLights-Radio_diag.gif

87-92 power window wiring
http://www.veryuseful.com/mustang/tech/engine/images/mustang87-92 PowerWindowWiring.gif

93 power window wiring
http://www.veryuseful.com/mustang/tech/engine/images/mustang93PowerWindows.gif

T5 Cutaway showing T5 internal parts
http://www.veryuseful.com/mustang/tech/engine/images/5_Speed_Cutaway_Illustrated.jpg

Visual comparison of the Ford Fuel Injectors, picture by TMoss:
http://www.veryuseful.com/mustang/tech/engine/images/Ford_Injector_Guide.jpg

Convertible top motor wiring http://www.veryuseful.com/mustang/tech/engine/images/mustang88VertTopMotorCkt.gif

Engine mounted fuel injector harness
http://www.veryuseful.com/mustang/tech/engine/images/mustangEngineHarness.gif

Location of the TPS, IAB, and the 10-pin connectors on a 5.0, picture by TMoss:
http://www.veryuseful.com/mustang/tech/engine/images/TPS_IAB_Pic.jpg

Starter circuit
http://forums.stangnet.com/attachment.php?attachmentid=21328&d=1080916057

Alternator diagram for 94-95 Mustangs.
http://www.veryuseful.com/mustang/tech/engine/images/Mustang-94-95-Alt.gif
 
Ended up being pinched injector wires on #8 by a vacuum connector on the underside of the upper intake. Traced it connector by connector until the short to ground went away, which helped isolate the issue to just the harness for the injectors, TPS, IA, EGR, etc.