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Re: 40 amp fuses continue tripping in a 1996 Chrysler...
The owner's manual should delineate which circuits each fuse pertains to. Are they fuses that are blowing or circuit breakers that trip and can be reset?
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In place of a fuse connect a bulb... bulb should burn. trace wire with a compass or a magnetic field app on smart phone till you found the problem, way easier than a new wiring harness as well as cheaper... :-)
It will help if you can identify the 40 Amp fuse that is being toasted when the key is turned.
I looked briefly at a fusebox diagram and found 3 circuits protected by a 40 Amp fuse. The Lamp circuit protects several circuits which have smaller rated fuses on each separate wire. The 40 Amp protection seems to be a safeguard if all the smaller circuits are active in total. Turning off the automatic headlights, should reduce power drain.
The next circuit is the Rear window defroster. Can easily pull 40 Amps, but once the 40 Amp fuse breaks, it should have no effect on the engine.
The last circuit, on the cars with Trailer Tow or Police package has a
40 Amp fuse on the Battery charge Relay. This is a remote possibility. But the engine should be able to run without an Alternator for several minutes using Battery power.
Have them check the fuel pressure. The Inertia switch could have tripped while the car was being repaired. It does not explain the wiring short, but can explain the no start condition.
Again, if the same 40 Amp circuit is overloading, identify the circuit with the fuse box diagram.
There is one circuit or more still active when the car is at rest. Connect a tester light between battery`s (-)terminal and ground cable. If there is an active circuit the light will be on. Unplug fuses one by one leaving them outside. When the light turns off note the number of the circuit/fuse and trace the problem. If several curcuits are active, this procedure shoulde reated. Usually simple things like the glove box light switch, or the luggagecompartment light switch cause this type of problems.
By connecting the O2 sensor wires together you have created a short to ground in the O2 heater circuit blowing the related fuse that is usually on the ASD circuit. Without a converter the check engine light will come on since the O2 sensors are no longer doing their job. If she doesn't mind the light being on, disconnect the sensors leaving all the wires an open circuit and replace the affected fuse. You can't trick the computer since it looks for a ramp voltage and compares the upstream to downstream O2 sensors to determine the proper air fuel ratio for any given driving condition. I hope this helps.
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