ABS - ABS/HDC Warning Lamp ON
No: 70/04/05/NASFGN LM206-07
Replaces: 70/11/04/NAS
Issue: 1
Date: 21 July 2005
Water Ingress into ABS Modulator
Connector
AFFECTED VEHICLE RANGE:
Range Rover (LM) Up to 4A161678
SITUATION:
ABS/HDC WARNING LIGHT ILLUMINATION
Water can enter the ABS modulator connection through the ground eyelet crimp under sustained usage in conditions of high water, particularly fording streams. The water ingress problem is more prevalent when the engine bay is hot. Water contamination can result in connector terminal corrosion and the ABS/HDC warning light being displayed on the instrument pack.
RESOLUTION:
INSTALL NEW-SPECIFICATION GROUND WIRES OR CONNECTOR HARNESS
Should a customer express concern regarding the above, refer to the procedure in this TIB. Inspect the connector for corrosion and replace either the ground leads and eyelet with a new set or if indicated the entire connector with a repair connector harness. The new configuration ground leads have a crimp sealed ground eyelet.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
NOTE:
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INSPECT HARNESS CONNECTOR FOR CORROSION
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM Range Rover/2004 > Workshop Manuals > Range Rover Workshop Manual Service Procedure > Bookmark "BRAKES/REPAIRS" link "ABS Electronic Control Unit (ECU)"
1. Refer to GTR Workshop Manual Section 70.65.01 and after proper preparation disconnect the battery ground lead.
2. Disconnect the ABS Modulator connector (C0506).
3. Inspect the ABS connector for corrosion at the ground wires (Cavity 1 and Cavity 5)
4. Inspect other wires in connector for signs of corrosion.
5. Inspect the ABS Modulator pins for signs of corrosion.
6. If ABS Modulator pins are corroded, clean the pins or if severely damaged, replace the modulator.
7. If only the connector ground wires are corroded go to "Install New ABS Connector Ground Leads" repair below.
8. If multiple connector wires are contaminated including the ground wires go to "Install new ABS Connector/Repair Harness" repair and replace entire connector, ground wire and splice all other harness wires.
INSTALL NEW ABS CONNECTOR GROUND LEADS
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM Range
Rover/2005 > Electrical Library. Then enter "C0362"
into the search window. Click "Document Content"
and click on Search. Select Electrical Library and
view found Connector Details.
1. Disconnect the ABS modulator ground eyelet at C0362. (Figure 1)
2. Release two clips and remove the top cover from the ABS connector. (left-hand clip arrowed Figure 2)
3. Slide back the two locking tabs, one at each end of the connector (arrowed Figure 3).
4. Remove the tape covering the ground lead back to the eyelet.
5. Release the cavity 5 securing tab using the tool from the harness repair kit and remove the brown wire (2.5 mm) from cavity 5. (Figure 4 and Figure 5)
6. Release the cavity 1 securing tab using the tool from the harness repair kit and remove the brown wire (4 mm) from cavity 1. (Figure 6)
7. Remove the two ground wires from the harness.
8. Position the new ground wires to the harness.
9. Install the 4 mm wire into cavity 1 and the 2.5 mm wire into cavity 5.
10. Slide back the two connector end locking tabs. (Figure 7)
11. Wrap the exposed harness wires with new electrical tape. (Figure 8)
12. Install the connector top cover.
13. Connect the ground eyelet at C0362 and tighten to 7-9 Nm (5-7 lbf.ft).
14. Install the connector onto the ABS modulator.
15. Install the battery ground cable.
16. Using T4, clear any stored fault codes.
17. Verify that the ABS/HDC warning light is no longer illuminated.
INSTALL NEW ABS CONNECTOR/REPAIR HARNESS
NOTE.
This procedure is required only if evidence exists of corrosion on multiple connector terminals. A repair kit is available which includes a replacement ABS modulator connector with a short wiring harness section. In cases where multiple terminal corrosion is evident, also check for corrosion of the modulator terminals and clean or renew if necessary.
1. Disconnect the ABS modulator ground eyelet.
2. Release the two clips and remove the top cover of the modulator connector. (Left-hand clip indicated in illustration in Figure 2)
3. Slide back the two locking tabs, one at each end of the connector (Figure 3).
4. Remove the harness tape from the ABS harness 100 mm (4 inches) past the ground wire breakout point to expose the individual wires of the harness.
CAUTION:
The ground wire assembly is part of the new connector repair harness. No splice is required to install the ground wires to the ground location.
5. Overlay the new harness repair section (YMQ500292) onto the vehicle ABS harness to gauge the overall installation length.
CAUTION:
The wire color selected on the new harness section and vehicle harness
MUST match exactly for each splice.
CAUTION:
Splices should be staggered over about 200 mm (8 inches) [100 mm before the ground wire breakout ground point, and 100 mm past the ground wire breakout point] to avoid bundling the connectors in one place.
6. Select matching wires from the vehicle harness and the repair harness and perform the following:
^ Cut the selected wire from the vehicle harness at a point permitting splicing to the selected repair wire.
^ If required trim the length of the wire from the repair harness.
^ Remove 4 mm (3/16 in) of wire insulation on both the vehicle harness wire and the repair wire to expose the conductor.
^ Join the matched wires, using the crimp joints and crimping tool from the Land Rover harness repair kit.
7. Repeat step 6 one wire at a time for all of the remaining un-spliced wires except the brown ground wires connected to the sealed eyelet.
8. Discard the connector removed from the vehicle harness.
9. Fully wrap the vehicle wiring harness using suitable wiring repair tape, covering the new crimped joints but ensuring that the ground lead is left free for 100 mm (4 inches) outside of the wrap.
10. Connect the ground eyelet and tighten to 7-9Nm (5-7lbf.ft).
11. Secure the connector to the ABS modulator.
12. Connect the battery ground lead.
13. Using T4, clear any stored fault codes.
14. Verify that the ABS/HDC warning light is no longer illuminated.
Disclaimer