Air Suspension - Height Sensor Connector Overlay Harness

No.: LA204-003

Issue: 1

DATE: May 15, 2006

SECTION: 204-05

Air Suspension Height Sensor Connector Overlay Harness

AFFECTED VEHICLE RANGE:

LR3 (LA) VIN: 5A000360 onwards

CONDITION SUMMARY:

NEW OVERLAY HARNESS SERVICE KIT FOR HEIGHT SENSOR CONNECTOR

Situation:

A service repair kit for the electrical connector to the air suspension height sensor is now available. Damage to the height sensor connector or connector wiring would normally have required replacement of the entire wiring harness. This service repair kit provides a short overlay harness and connector that may be used to repair connector damage.

Action:

Should the air suspension control module contain a Diagnostic Trouble Code (DTC) that is diagnosed as damage to the electrical wiring in the vicinity of the sensor connector or to the connector itself, refer to the Repair Procedure detailed in this bulletin to replace the sensor connector where appropriate.





PARTS





WARRANTY

REPAIR PROCEDURE

INSTALL AIR SUSPENSION HEIGHT SENSOR CONNECTOR OVERLAY HARNESS

NOTE:
GTR lookup sequence is as follows:

GTR Home> NAS > Service Information/LA - LR3> Workshop Manuals> LR3 Workshop Manual> Bookmark> "Electrical/Battery and Charging System/414-00: Charging System - General Information"> Link> "Specifications"

1. Refer to Global Technical Reference (GTR) section 414-00, and disconnect the battery ground cable.








2. Disconnect the existing electrical connector. (Figures 1 and 2)

3. Unclip a sufficient length of the connector wiring harness to allow access.

CAUTION:
The overlay harness wires must be of sufficient length to repair the damaged wiring.

The overlay harness wires must be cut so the vehicle harness remains at the original length.

4. If the sensor connector wiring is damaged, match the length of the overlay wiring to the damaged wiring to ensure the overlay harness is of sufficient length for repair.

5. Remove a sufficient amount of the existing wiring bundle insulation to gain access.

NOTE:
It is advisable to cut only one of the three connector wires at a time and to stagger each wire splice to allow easier repair.

CAUTION:
The colors of the overlay harness wires may vary from the original equipment wiring. Care should be taken to ensure the pin wires from the existing sensor connector are matched to the corresponding pin wires of the overlay connector.

6. Refer to GTR Electrical Library - Connector Details and locate the wire leading to 'pin one' of the appropriate vehicle height sensor connector.

7. At a suitable position along the vehicle harness, cut 'pin one' wire.





8. Remove approximately 10 mm (0.40 in) of insulation from the vehicle harness wire. (Figure 3)





9. Slide a section of "heatshrink" sleeving over vehicle harness wire. (Figure 4)

NOTE:
The crimping tool must be set to the correct jaw size for the Butt Splice wiring connector used.

10. Crimp the vehicle harness wire to one end of the Butt Splice connector. (Figure 4)

11. Locate the corresponding pin wire of the overlay harness.

12. Cut the overlay harness wire to an equal length of wire cut from the vehicle sensor connector.





13. Remove approximately 10 mm (0.40 in) of insulation from the overlay harness wire. (Figure 5)

14. Crimp the open end of the Butt Splice connector to the corresponding overlay harness wire.

15. Ensure both wires are securely crimped to the Buff Splice connector.

CAUTION:
When using the heat gun, care must be taken to avoid damage to surrounding areas.

16. Slide the 'heatshrink' sleeve over the Buff Splice connector.





17. Using a hot air gun, carefully apply heat until around both ends of the sleeve until glue appears at both ends. (Figure 6)

18. Ensure the 'heatshrink' has completely sealed around the circumference of the wire sheathing of both connector wires.

19. Repeat steps 7-19 to wires at pins 4 and 5 of the vehicle harness and overlay harness connectors.

20. After completing the splice to all three pin wires, discard the damaged sensor connector/section of harness.





21. Tape the repaired area to within 10 mm (0.40 in) of the new connector. (Figure 7)

22. Route and secure the overlay harness to original locations.

23. Connect the new sensor connector to the height sensor.

24. Refer to Global Technical Reference (GTR) section 414-00, and connect the battery ground cable.

25. Clear DTCs logged in the air suspension control module.

26. Verify correct operation of the air suspension system.





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