Help...electrical problems

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777Disco

Member
Posts
57
Location
Buckinghamshire
Hi,

I have been working on an electrical problem for about a week now on my k reg 200 tdi discovery.

Some of this info may not be relevant but just in case here is what happened and is happening.

My lands was sat parked up for a couple months awaiting an mot, was periodically running it in an effort to keep e battery charged, however on the day of the mot it was completely flat and couldn't even jump it using my jump pack.
Went a bought a new battery from a local supply place, got it back was surprised to see it was smaller than last battery. Original had 700CCA 90ahr he new one is 540cca 70ah. But put it in landy worked and off to the mot.

At mot it failed on a couple of things rear antiroll bar, rear brake light and a headlight fault.

The issue with the headlights was when full high beam was switched on, drivers headlight went out completely.

A previous owner had wired in some spot lights to come on with the headlight high beam, with a switch inside the cab to turn them off if not wanted. Headlights and spotlights have worked fine for the several years I have had the car in this fashion.

Upon looking at the headlight fault, was met with various loose and corroded connections behind the head light bulbs and one of the spotlights also had a broken connection. Found a pair of the same spot lights for sale brand new so swapped them over and wired up the same. I also wired in new headlight connectors.

For some reason the earths were wired in series between the two spotlights and was causing some issues, so I ran a seperate Earth from the second spot light which seems to of fixed things and everything was working fine.

Was running through testing sidelights, headlights main beam and his beam, with spotlights on and off and when I turned on the ignition at one stage no lights whatsoever!

I went through checking all the connections, cleaning every earth I can find and replaced every fuse in the fuse box and nothing.

A bit more head scracthing and then happened to wiggle a wire in the back of a relay in the engine bay which had been wired by a previous owner into the spotlight circuit.

Everything then seemed to start working again! As other electrical systems had also failed went through testing them and everything was good until it got to pressing the horn or flashing the headlights by pulling the indicator stalk towards the steering wheel. This caused the radio to cut out and interior light to flash and headlights to stop working. After a little while most things were working. Except the horn or headlight flash.

I parked the landy up and a couple of days later when I came home from work could hear a noise coming from the electric aerial, it was pulsing as if it was getting power and trying to raise but the power was cut before it raised. It was too dark to fiddled but luckily with unlocking the car turning lights on and off it settled.

Again a bit of head scratching and decided to replace the relay I wiggled before, all wired up worked fine.

Until pressing the horn or attempting to flash the headlights.

I have since discovered that if I disconnect and reconnect the radio it seems to reset everything to working. - minus horn and headlight flasher.

I disconnected the radio head unit and as headlights etc were working parked it up last night. This morning headlights don't work!

After much research on the Internet was almost excited to read my problem could be caused by fusible links, I have checked the battery positive strap and no sign of any fusible link! Can only assume mine done not have any fitted or has been to,aced by a previous owner.

Considered an issue with the stalk itself, however on checking cannot see anything obvious all connections seem in place etc.

Checked the back of ignition barrel, all wires seem in place and not damage to connections.

There is a random broken black wire under the dash, it looks like it's been cut rather than a break or burn so am not sure it it has been superseded by a different wire from a previous owners repair, it appears to go into a black metal box which sits under the fuse box. It has other wires going in and out of it, not sure if it's something to do with the alarm ?

Anyone know what this metal box could be?

What could e broke wire connect to?

Any other ideas or things to check?

At the moment switching on headlights, pressing the horn activate the interior light randomly!

Apologies for the lengthly post but it has been a week of trying to fix this issue, any help or ideas greatly appreciated!
 
Hi, go further on the positive lead, a friend of mine have had the same issue and we found them hidden down below after he removed the battery tray, New Page 1 , though you should check all the important earth points too
 
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Why check the battery strap? when fusible links when they are buried within the main wiring harness on the 200 series.
There's no metal boxes in a disco, any boxes you may find are ecu's and they are plastic so it crystal ball time with "metal boxes". :)
 
on my friend's 200tdi the lead went under the battery and we couldn't get to the fusible leads without removing the tray... though his was bodged all over too
 
Thanks for the replies,

Discool where is the main wiring harness? Looking at the info I have seen on the forum, including the link from sierrafairy it says the fusible links are in the positive lead?

I am hoping you are right and I can find the fusible link, somewhere!

I have felt along the battery positive lead as far as I can and no joys.

The metal box is defo there, I don't know if it's something to do with the alarm perhaps.

I'll try and upload a pic of the box sat below the fuse box, and of the random broken black wire see if anyone can identify.

If any one has a picture of where the fusible links are that would be great, or even a generic engine picture with an arrow would do
 
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8ada61d94050ab87b2c334fcb5af82ea.jpg


The mysterious box under the fuse box.

9330615b2361c860cbbe19d460029a54.jpg


The broken wire leading into this box
 
Okay the main wiring harness is by the battery, it's inclosed in fabric and then only a few inches from the battery u will see a lump in the fabric that's where the links are.

To access the links u will have to carefully cut the fabric open, they will be corroded and broken if faulty, the way to rectify the problem is cut out what u have and then install a 300 series engine bay fuse box which includes the fusible links, (although if u search the www there's a kit that u could that is used for the RRC that had a similar problem) some alterations to the wiring will be required to extend the existing wiring to enable the fuse box to be fitted.

All the above assumes that u have faulty fusible links, but u still have to gain access to then to find out...that's cutting the fabric of the wiring harness with a Stanley knife to find out.
 
Hi, if you check the wiring loom above drivers inner wing under the bonnet, this is normally broken and corroded if so it normally gets hot with the headlamps on
 
seems like that one at the bottom which is full of dirt if i see well that it becomes thicker at one point... i'm on my telephone and can't see much
 
Turns out you guys were right! Once I found the right place I opened it up and found......

0c2cddc17df4d67af3d14f0ed59f7d8e.jpg


One broken fusible link wire!

Connected the two ends together to test and everything is back to working!

I hope that someone else in the future finds this thread useful!

Thank you for your help guys!
 
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