GEMS Disco 1 Water in ECM TSB

[Joey]

AFFECTED VEHICLE RANGE:
DISCOVERY (LJ) * ALL GEMS EQUIPPED *

SITUATION:
WATER LEAKS INTO GEMS ECM CONNECTORS

In some cases it has been found that water can leak into the GEMS control unit connectors and cause corrosion. Driving off-road is the primary cause of the water ingress. This corrosion can cause a number of driveability symptoms, which in turn can cause customer concerns.

RESOLUTION:
IMPROVE WATER LEAK PROTECTION

Whenever investigating a driveability problem, the ECM connectors should be examined for corrosion and water intrusion. Use the following procedures to reduce the chance of corrosion forming in the three ECM connectors and to improve protection of the GEMS ECM.

NOTE :The repairs outlined in this TIB are to be performed to resolve customer complaint of the symptoms described.

PARTS INFORMATION:

LRN2274-006 Grommet * Qty 1 *

LRN236X1AH1 Plastic Plug * Qty 4 *

AMR5619 Grommet * Qty 1 *

YOO3100PMA "Fir Tree" Fastener * Qty 2 *

MUC4177 Seal * Qty 1 *

WARRANTY CLAIMS:

18.20.89/27 Time 0.40 hrs.
Inspect GEMS ECM, and seal against water leaks.

COMP CODE: 7G1H

Normal warranty policy and procedures apply

REPAIR PROCEDURE:







1. Remove fir-tree fasteners from ECM cover and remove the cover (Figure 1).

CAUTION :Whenever the connectors are removed from the GEMS ECM, care must be taken that the anti-backout devices remain in the harness connectors.

2. Remove the ECM connectors and examine for water intrusion or corrosion.

3. Remove the two nuts securing GEMS ECM to body and remove.








* 4. Install plastic plugs LRN236X1AH1 in holes in the inner fender behind ECM (Figure 2). *








* 5. Replace grommet where the washer hose passes into the air intake plenum with grommet LRN2274-006 (Figure 3). *

6. If the vehicle is equipped with unused heated windshield wiring, inspect the fit of the grommet for the heated windshield wire.

7. If the windshield wire grommet does not seal well to the cable, replace the grommet as follows:

^ Pull the wire harness and grommet back into the intake plenum.

^ Insulate connectors with tape and secure removed harness to the main harness.

^ Ensure that the harness does not contact ground.

^ Install solid grommet AMR5619 into the hole in the plenum where the wire used to be.


NOTE :The plenum water drains are round and approximately 1 inch in diameter.

8. Check the water drains in the plenum to ensure that they are not blocked with sealant or debris, and clean as necessary.

9. When servicing the GEMS ECM at any time ensure that the wire harnesses leading to the ECM are routed in such a way as to have a length that is lower than the ECM connectors in order to form a "drip loop."

10. Reinstall GEMS ECM and secure with nuts.

NOTE :Always replace the GEMS ECM protective cover fir-tree fasteners with new ones (YOO3100PMA) to ensure proper positioning of the cover.

11. Install GEMS ECM cover.

12. Refer to Figure 1 and install fender seal MUC4177 along the fender flange, abutting the existing plenum seal