SRS Harness - Replacement Procedure
01/09/9576/24/95/US
SUBJECT:
SRS Harness Replacement Procedure
MODEL
Range Rover Classic
Discovery
AFFECTED VEHICLES
LP
LH 647645 onwards
LJ All
LD
DETAIL
Possible reasons for harness replacement are as follows:
1. The car was involved in an accident.
2. TestBook diagnosis suggests harness replacement.
3. During diagnosis an open circuit is detected in the harness (the most common).
We ask dealers to adhere strictly to the following procedure and not to attempt any shortcuts (HVAC units and fascia must be removed in their entirety).
ACTION REQUIRED
Upon requirement of SRS harness replacement follow procedure below.
PARTS INFORMATION
AMR 3993 Discovery SRS Harness (Qty. 1)
AMR 3667 Classic SRS Harness (Qty. 1)
PROCEDURE
NOTE:
Review safety precautions regarding the SRS system as outlined in the Workshop manual.
Preparation
1. Place vehicle on flat ground with road wheels in the straight ahead position.
2. Automatics - Chock wheels and place shifter in the neutral position.
3. Ensure that the radio security code is available and disconnect both battery terminals.
4. Remove the closure panels in the top of each footwell.
5. Connect and activate A/C refrigerant recovery equipment to discharge A/C system. Continue working.
Remove Console
1. Discovery - remove transfer box shifter knob and boot.
Classic - remove transfer box shifter knob only.
2. Manual Box - remove shift knob and boot.
Autos - remove PRNDL trim by lifting at front edge.
3. Discovery - remove rubber mat. Remove window switch trim. Unscrew 4 screws securing switch panel and disconnect switches.
Classic - remove wood insert. Disconnect window switches.
Hint:
To aid in reassembly, record the position and color of each window switch connector.
4. Slide parking brake boot up handle to expose parking brake handle assembly.
5. Remove parking brake cable clevis pin from handle assembly.
6. Remove 5 bolts securing center console and remove. Disconnect cigarette lighter connections.
7. Remove bracket in front of transfer box shifter.
Remove Airbag Modules
1. Remove 2 tamperproof torx screws at back of steering wheel. Disconnect and remove drivers module and stow properly.
2. Swing glove box down by lifting the stop levers into the 2 cutouts. Disconnect the red 2 pin connector in between relays.
3. Remove the 4 torx bolts and remove airbag module. Stow properly.
Remove Hinged Panels
1. Remove 4 bolts securing glovebox hinge to fascia and remove glovebox.
2. Remove 4 bolts securing fuse box cover hinge to facia and remove fusebox cover.
Remove Radio
1. Unscrew the 2 radio locks using tool RTC7657 and remove radio.
Remove Column Components
1. Mark position of the steering wheel to the shaft. Disconnect the cruise control switches and free wiring from clips.
2. Unscrew steering wheel nut by 3 turns. Pull on steering wheel until it's free from the column splines.
3. Remove the nut. Remove the steering wheel while carefully feeding the rotary coupler wiring through the steering wheel.
4. Remove ignition key from column lock.
5. Remove 3 screws securing column shroud to column. Pull halves of the shroud apart and remove.
6. Unplug connections to rotary coupler. Pull coupler from switch pack.
7. Remove electrical connections to switch assembly. Loosen switch assembly lock screw by 5 turns. Press in on screw until it is flush with the switch housing. Remove switch assembly by pulling it straight off.
Facia Removal - Preparation
NOTE:
The facia is removed as an assembly with most of it's components still attached.
1. Unscrew 4 torx bolts securing drivers knee bolster to A-frame. Remove knee bolster.
2. Disconnect 5 multi-pin connectors located to the left side of the heater box.
3. Disconnect single pin connector at the lower left corner of the fuse box.
4. Disconnect red 6 pin connector below steering column. Free this connector so that it hangs freely outside of the facia opening.
5. Disconnect 18 pin connector from fuse box.
6. Remove 2 screws securing relay bracket below passenger airbag module. Move relay bracket aside.
7. Unscrew the 1 nut securing relay bracket in right footwell and swing bracket down.
8. Disconnect heater control cables from heater box. (2 right, 1 left).
9. Classic - Unplug memory seat lead connector under passenger seat and feed the harness back up to facia.
Remove facia
1. Remove both kick panel finishers.
2. Remove the 2 bolts securing the facia to the right A-pillar.
3. Loosen the 2 bolts securing the right A-pillar bracket to the facia. Slide the bracket fully inward, and tighten the bolts.
4. Repeat steps 2 and 3 for left side.
5. Remove the 4 bolts (2 bolts per side) securing the facia to the transmission tunnel.
6. Remove the strap between the A-frame and the left tunnel bracket.
7. Remove 4 bolts below the passenger airbag that secure the facia to the firewall.
8. Remove 4 nuts below instrument pack.
9. Remove facia assembly from vehicle.
HVAC unit
1. Disconnect 2 blower connectors (2 pin and 8 pin).
2. Remove bracket at the top of the blower unit.
3. Remove 2 nuts securing the bottom of the blower unit. Remove blower assembly from vehicle.
4. Release pressure from the cooling system. Disconnect the heater hoses and plug. Plug the heater core inlets.
5. Confirm that the A/C system is empty. Disconnect the refrigerant pipes from the evaporator. Plug openings to prevent dirt ingress.
6. Remove 2 rear footwell ducts.
7. Disconnect drain tubes on both sides of heater box.
8. Disconnect 10 pin connector to right of heater box.
9. Remove 5 heater box bolts. Remove heater box.
SRS Harness
The SRS harness can now be accessed. Replacement of the harness is self explanatory with the following guidelines.
1. The DCU connector is released by sliding the yellow locking device rearward. To connect, place the connector on the DCU as far as it will go and slide the locking device forward.
2. The crash sensor seal and anti-backout device may stick inside the sensor cavity upon removal. Remove these parts from the connector before fitting the new harness.
3. The under hood section of the harness is fed into the passenger compartment for removal.
4. The replacement SRS harness must be routed exactly as the original harness.
5. The harness must never be cut or repaired.
Reinstallation
Follow procedures in reverse order for reinstallation of facia and components. After reinstallation test drive vehicle to test for any rattles or noises that might be introduced by the fact that many components were disturbed during SRS harness replacement.
WARRANTY
Normal warranty policy and procedure apply.
COMP. CODE
6T0Z
SRO
86.70.63 SRS Harness renew 6.35 hours.