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Thread: Redoing glow plug wiring - What size fuse to EACH glow plug?

  1. #1
    Join Date
    Aug 2007
    Springfield, Missouri U.S.A.

    Default Redoing glow plug wiring - What size fuse to EACH glow plug?

    I am redoing some of the wiring and things on my 6.5 Suburban and the glow plug wiring is included in that. Factory, they use a fusible link to each glow plug. I don't like fusible links and on top of that the connectors and wiring are all dirty and looking in pretty bad shape. Therefore, I have purchased 8 new 16 gauge inline fuse holders (waterproof, using ATC fuses) and some 16 gauge wire and various connectors. I am going to build a new glow plug harness, with a normal blade type (ATC) fuse for each individual glow plug (the way the factory had it, except they used fusible links to each glow plug instead of fuses). I will correctly route the wiring, solder the terminals, heat shrink the joints, etc. But I would like to know if a 10 amp fuse will be enough for each glow plug? I really think its probably too much honestly, because each bank of 4 glow plugs had a single 18 gauge wire connecting each glow plug fusible link to the glow plug relay. That seems way too small to me, but its worked for 20 years so I guess its not too bad. I am going to use a single 12 gauge wire from the relay to the 16 gauge fuse holders, and then 16 gauge wire from the fuse holders over to each glow plug. There is also a single 6 or 8 gauge wire (cant remember which) wire running from the glow plug relay to the under hood fuse box, which had a fusible link in between it and the relay itself also. I have purchased a 6 gauge inline maxi-fuse holder that I am going to install in place of the fusible link going to the glow plug relay. Currently, I have a 50 amp fuse to use in that (Which upon further thinking, may also be too much, if each glow plug doesn't need 10 amps and I use 5 amp fuses, as 5 amps x 8 plugs is 40 amps. I could also use 7.5 amp fuses which would require a 60 amp fuse.

    I would like to hear input from you guys about this plan. Look forward to hearing from you.

    1996 Chevy Suburban 1500 4x2 6.5 "F" 4L80E 322,000 Miles. New Bosch injectors in 2010, New SSDS injector pump in 2012. Custom remote PMD mount.

    1974 Ford Pinto Wagon With 1991 Mustang 2.3 EFI/DIS and Stock Pinto 4 Speed - Ford 8" rear w/ 3.00:1 gears. 100k Miles

    1980 Volvo 265 With 1997 S-10 4.3 Vortec V6 and 700R4 Automatic transmission with corvette internals. Dana 30 rear with 3.54 gears. 38k showing on odometer since it was reset to zero upon its restoration.

  2. #2
    Join Date
    Feb 2007


    You seem to have it some what worked out. The fuses are to stop the wires going on fire, in the case of a short, that is why there are fusible links after the wires are divided and become smaller. If you google safe working current for a wire size, you can use a fuse that size for each wire that size.
    Grant H.
    1995 6.5 turbo GMC K2500 extra cab 4x4 pickup, PMD under bumper, mechanical wastegate, 228,000 miles, rebuilt engine, 4.10 diff, 16 mpg
    1994 6.5 turbo GMC K2500 4x4 suburban #9 resistor, PMD in the bumper, mechanical waste gate, 226,000 miles, 3.73 diff, 16 mpg
    1982 4x4 shortbed 6.2 Chev 260,000 miles untouched motor 17 MPG 4.27 diff. Best thing I ever owned, since 1992.

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