Electrical - Front Door Electrical System Malfunctions
No: LA-418-001Issue: 2
Date: 13 Mar 2006
SECTION: 418-02
Front Door Electrical System Malfunctions
AFFECTED VEHICLE RANGE:
LR3 (LA)
VIN: 5A000360 to 5A350570
Updated information is shown by asterisks and shaded areas.
CONDITION SUMMARY:
MIRROR/SPEAKER/CENTRAL LOCKING/PUDDLE LAMP/APPROACH LAMP/GLASS ISSUES
The customer may express concerns of electrical issues with the function of the exterior door mirror, audio door speakers, central locking, puddle lamp/approach lamp or the front door window going down on its own.
Cause:
One or both of the front door harnesses may be chafing against the lower edge of the door panel.
Action:
Should a customer express concern, both front door harnesses are to be checked, repaired if indicated, and the harness retained in position with a cable tie. Follow the Repair Procedure outlined below.
PARTS:
TOOLS:
WARRANTY:
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. *The causal part number in this edition of the bulletin has been changed.*
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
INSPECT AND IF INDICATED REPAIR DOOR WIRING HARNESSES
WARNING:
SRS sensors are located in the doors. Before work is undertaken on door wiring the battery must be disconnected and the SRS system allowed to deactivate as described in the Workshop Manual.
1. Disconnect battery and follow all warnings and cautions relating to working on SRS components.
2. Open the front doors.
3. Release the wiring grommet from each front door. (Figure 1)
4. Carefully inspect the door harnesses for any signs of chaffing.
NOTE:
If the wiring cannot be repaired, a new wiring harness will have to be installed using a separate Warranty Claim.
5. If no sign of chaffing is apparent perform the following on undamaged harnesses:
^ Install a new cable tie to the wiring harness.
^ Position the new tie on the lower edge of the inner panel and push fully home. (Figure 2)
^ Install the grommet.
6. If any sign of chaffing is apparent on either side door harness and the wiring can be repaired, perform the following:
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LA LR312006 >
Workshop Manuals > Discovery 31LR3 2005 Workshop
Manual > Bookmark "Body and Paint/501-11 Glass
Frames and Mechanisms" > Link "Front door window
Regulator and Motor" (86.25.03)
^ Remove front door widow regulator and motor (see
Global Technical Reference GTR Workshop Manual, section 501-11).
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LA LR312006 > Workshop Manuals > Discovery 31LR3
2005 Workshop Manual > Bookmark "Lighting/417-01 Exterior Lighting" > Link "Side Turn Signal Lamp (86.40.53)"
^ Remove side turn signal lamp (see GTR Workshop Manual, section 417-01).
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LA LR312006 > Workshop Manuals > Discovery 3/LR3
2005 Workshop Manual > Bookmark "Body and Paint/501-05 Interior Trim and Ornamentation" > Link "Cowl Side Trim Panel (76.13.27)"
^ If repairing the driver side, remove cowl side trim panel (see GTR Workshop Manual, section 501-05).
^ If repairing the passenger side, open the glove compartment and release compartment latch stops.
7. Perform the following repair on either side with a damaged but repairable harness: (Figure 3)
^ Release the grommet and retaining clip, and disconnect the electrical connector from the door wiring harness to the body wiring harness.
^ Disconnect the door latch electrical connector.
^ Disconnect the mirror electrical connector and release from door.
^ Disconnect the door side impact sensor electrical connector. (Figure 4)
^ Release the grommets and clips and remove the door wiring harness.
^ Perform the following wire repair on any damaged wire:
NOTE:
Carry out the wiring repair using the Wiring Harness Repair Kit (418-S587).
8. Place the damaged door harness on a suitable bench and perform the following:
^ Cut the wire 10 mm either side of the damaged area.
^ Cut new wire to length of removed section.
^ Position the heat-shrink and splice the new section of wire to the harness.
^ Position the heat-shrink over the splice connection and apply heat, using a suitable heat gun and a heat shield. (Figure 5)
^ Perform Step 7 on any remaining chaffed wires.
9. Install the repaired harness as follows:
^ Install the new cable tie to the wiring harness.
^ Locate the cable tie on the lower edge of the inner panel and push fully home, reinstall the grommet. (Figure 6)
^ Install the door harness.
^ Install the clips and grommets.
^ Connect the door side impact sensor electrical connector.
^ Install the mirror connector to the door and connect electrical connector.
^ Connect the door latch electrical connector.
^ Connect the door wiring harness to the body wiring harness, connect electrical connector, secure clip and install grommet.
10. If repairing the passenger side, install the glove compartment latch stops and close the glove compartment.
11. If repairing the driver side, refer to GTR Workshop Manual Section 501-05 and install the cowl side trim panel.
12. Refer to GTR Workshop Manual, Section 417-01 and install the side turn signal lamp.
13. Refer to GTR Workshop Manual Section 501-11 and install the front door widow regulator and motor.
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