Brakes/Suspension - Erratic Suspension/EPB Operation
No.: LS-204-003Issue: 1
Date: January 04, 2006
SECTION: LS204-05
Air Suspension Connector Water Ingress
AFFECTED VEHICLE RANGE:
Range Rover Sport (LS) VIN: 6A9000129 to 6A903766
CONDITION SUMMARY:
INCORRECT OPERATION OF EAS OR EPB
A customer may report incorrect operation of the air suspension or the electronic park brake (EPB) system. Air suspension diagnosis may determine that there is intermittent power supply to the air suspension compressor, or intermittent operation of front RH corner valve. EPB diagnosis may reveal a low voltage fault coded in the EPB module as well as constant or flashing amber EPB warning lamp illumination. Water ingress into the air suspension connector C2528 located at left-hand front wheel arch may be the cause.
Action:
Should a customer complain of the described symptoms, refer to the Repair Procedure detailed in this bulletin.
PARTS
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.
REPAIR PROCEDURE
REPLACE CORRODED CONNECTOR WITH NEW CONFIGURATION
NOTE:
Early production vehicles may have had this connector removed and the wires joined. In instances (not related to this bulletin) where it becomes necessary to separate this joint, the repair kit for this bulletin can be used to install a new connector.
NOTE:
GTR lookup sequence is as follows:
GTR Home>NAS>Service Information/Range Rover Sport/2006>Workshop Manuals>Range Rover Sport 2005 Workshop Manual>Electrical/Battery and Charging System>Bookmark "414-00, Charging System - General Information" > Link "Specifications"
1. Refer to GTR Section 414-00 and disconnect the battery ground cable.
2. Remove the LH front wheel and tire.
NOTE:
GTR lookup sequence is as follows:
GTR Home>NAS>Service Information/RangeRover Sport/206>Workshop Manuals>RangeRover Sport 2005 Workshop Manual>Bookmark "501-02, Front End Body Panels"> link "Fender Splash Shield".
3. Refer to GTR section 76.10.48 and release the rear lower edge of the LH fender splash shield.
4. Position the fender splash shield aside in order to gain access to the electrical connectors.
5. On vehicles fitted with rear air conditioning, release the "P" clip securing the air conditioning pipe to allow access to the connector. (Figure 1 shows correct routing of the wiring harnesses in front of the air conditioning pipes.)
NOTE:
GTR lookup sequence is as follows:
GTR Home>NAS>Service Information/RangeRover Sport/2006>Electrical Library>Range Rover Sport Electrical Reference Library>Bookmark "CONNECTOR DETAILS"> Link "C2527 Chassis harness to engine compartment harness".
6. Locate and remove from its mounting bracket the blue connector C2527/C2528 at the rear of the wheel arch. (Figure 2)
7. Cut the electrical wires as close as possible to the connectors and discard the old connector.
8. Reposition the wire identifiers if installed.
9. Select the correct size shrink wrap for the wire size and install a length of harness shrink wrap to each harness wire.
CAUTION:
Corroded (pitted) wire conductors must not be repaired if the corrosion is deeper than 150 mm (6 inches) from the wire end. Contaminate (discolored) wires may be used after cleaning off the corrosion.
10. Strip the wire insulation to expose the conductors on all exposed wire ends.
^ Check the exposed conductors for corrosion (pitting) or contamination (discoloration).
^ If corrosion (pitting) has occurred more than 150 mm (6 inches) from the original connector location, cease this repair and replace the affected harness.
^ If contamination (discoloration) is less than 150 mm (6 inches), cut and clean the contaminated wire strand leaving enough exposed wire for the crimp connector.
CAUTION:
The electrical wires must be connected to the same wire color or the same tag IDs.
NOTE:
It is important that the female half of the blue connector is connected to the end of the harness on the car that is routed from the grommet on the inner wheel-arch (the same as the original connector).
11. Install the new harness electrical connector joining the - matching color and size wire ends using the correct size crimps provided in the repair kit - one size for each wire size. (Figure 3)
CAUTION:
Care must be taken when using the heat gun to avoid damage to surrounding areas.
12. Position the harness shrink wrap over each crimped connector.
13. Apply heat with a suitable heat gun until the shrink wrap is secure. (Figure 4)
14. Using a suitable harness repair tape, wrap the new crimped joints.
15. Connect and secure the electrical connector to the retaining clip.
16. Secure the repaired harness to prevent noise or rattles.
17. On vehicles with rear air conditioning, secure the "P" clip.
18. Refer to GTR Section 501-02/76.10.48 and install the LH fender splash shield and fender molding.
19. Install the LH front wheel and tire.
20. Refer to GTR Section 414-00 and connect the battery ground cable.
21. Check the air suspension for correct functionality.
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