Fusible link-repair

FUSIBLE LINK-REPAIR

Model

Range Rover Classic Discovery

Affected vehicles

All V8 derivatives Range Rover from LH 610295 to LH 647644 and Discovery from LJ 034314 to LJ 081990

Date

1994-10-31

Reference

31/10/94

Bulletin text

Fusible Link-Repair

MODEL AFFECTED VEHICLES

Range Rover All V8 derivatives Range Rover from LH 610295 to LH Classic 647644 and Discovery from LJ 034314 to LJ 081990 Discovery

DETAIL

From the above VIN numbers a design initiative introduced a new electrical harness which included a number of fusible links in close proximity to the battery. A number of reports have been received which have indicated that when a fusible link fails a replacement link is sometimes difficult to obtain and necessitates the replacement of the complete harness. To overcome this difficulty a service kit has been developed which includes all the fusible links attached to the battery cable and allows a cost effective repair to be carried out.

The fitment of this kit should be carried out by a qualified automotive electrician.

ACTION REQUIRED

Upon failure of a fusible link firstly locate the cause of the failure and repair as necessary. Replace the failed fusible link using the service kits identified below.

PARTS INFORMATION

AMR 3927 Discovery kit AMR 3928 Range Rover kit

PROCEDURE

1) Disconnect the battery positive and negative leads. 2) Locate the fusible links in the positive battery lead, covered by an expandable gauze sleeve. 3) Remove the tape wrap from the gauze sleeve and cut the gauze from the harness to expose the fusible links.

Note: Discovery-has 8 off 1 mm fusible links and dependant on the specification of the vehicle utilises upto all 8 of the links. Range Rover-has 8 off 1mm and 2 off 2mm fusible links and dependant on the specification of the vehicle, utilises combinations of 1 and 2 mm links. Identify which links are used and cut off the leads that are not used as close to the main cable as possible and insulate.

Continued.....

31/10/94

86/16/94/EN

WARRANTY

Normal warranty policy and procedures apply.

COMP. CODE

7Y1T

SRO

86.15.89/26 Replace fusible link 00.40 hour

Fusible Link Repair

MODEL AFFECTED VEHICLES

Range Rover All V8 derivatives Range Rover from LH 610295 to LH Classic 647644 and Discovery from LJ 034314 to LJ 081990 Discovery

4) Cut each positive lead adjacent to the existing splice joint (on the main harness side of the splice). Ensure the cut is made through cables that are in good condition. 5) Fit the large gauze sleeve to the main harness and push back until the harness leads are exposed. 6) Trim back the insulation on the main harness leads 6 mm from the cut end. 7) Ensuring that the new fuse link selected matches the size (diameter) of the old, cut the new fusible link to a length appropriate to the positioning of the new individual splice joint. Trm back the insulation on the fusible link to 6 mm from the cut end. 8) Cut suitable lengths of gauze sheathing (to cover the complete length of the fusible link) to replace any damaged individual gauze sheaths and push back over the fusible links. 9) Fit a heat shrink sleeve over the individual main harness leads.

10) Using the inline splice overlap and crimp the individual fusible link to the appropriate main harness lead. 11) Solder the crimped leads together to provide a secure joint. 12) Position the heatshrink sleeve over the spliced joint and using a heat gun shrink the sleeve over the crimped/soldered joint. 13) Pull back the individual gauze sleeve to cover the full length of the fusible link. NOTE: Repeat operations 1 to 13 for the remaining fusible links.

14) Pull back the large gauze sheath to cover the complete length of the link and securely tape the ends of the sheath to the main harness. 15) Reconnect the battery and re-input the radio CATS code.

31/10/94 86/16/94/EN