Fusible Link - Replacement Procedure
Bulletin: P91-014Section: Product
Dated: 11/11/91
Applicable to: USA, Canada
SUBJECT:
FUSIBLE LINK REPLACEMENT PROCEDURE
Fusible links in the 1992 Range Rover main wiring harness protect the circuits by providing a "weak link" in the main feed wires from the battery.
14 and 16 gauge replacement fusible link wire is available at most auto parts stores in 20 and 30 foot spools. Since each link is only 3-5 inches long, a spool of each size should last indefinitely.
Replacement
First, use the 1992 Workshop Manual wiring diagram or the 1992 ETM to isolate the failed circuit. Identify and repair the cause of failure. Normally, this will be a short to ground between the link and a fuse or fuses in the circuit.
Once the failure has been isolated and repaired, replace the fuse link as follows:
1. Slide back the protective mesh cover covering the link bundle. This is directly behind the battery.
2. Use a test light to identify the failed link.
3. Disconnect the negative battery cable and remove the failed link section and it's individual protective mesh sleeve.
4. Strip 3/4 inch of insulation from the ends of the cut harness wires.
5. Cut and strip the ends of a piece of replacement fuse link approximately one inch longer than the original. Slide the protective sleeve over the new link.
6. Join and solder the link to the harness ends and cover with heat shrink tube. DO NOT USE CRIMP ON BUTT CONNECTORS OR SCOTCH LOK'S.
7. Slide the protective mesh cover over the link bundle and secure with electrical tape.
NOTE:
Never replace fusible links with ordinary wire or with fuse link wire longer or smaller than that removed.
Warranty Information
Service Type: WW
Repair Code: 7Y1T
Labor Operation: 867000 .65 hours