Air Bag System - Multiple DTC's Set
No: LS501-018*Issue: 2*
Date: 20 Dec 2006
* ISSUE '2' CHANGES ARE HIGHLIGHTED WITH GREY BACKGROUND AND ASTERISKS
SECTION: 501-20B
Supplemental Restraint System Overlay Harness
AFFECTED VEHICLE RANGE:
Range Rover Sport (LS) VIN: 6A900129 onwards
CONDITION SUMMARY:
OVERLAY HARNESS REPAIRS TO SUPPLEMENTAL RESTRAINT SYSTEM (SRS) WIRING
NOTE: Service repair harnesses are now available to repair sections of the fascia/body SRS wiring harness without replacement of the complete harness.
The Worldwide Diagnostic System (WDS) may display Diagnostic Trouble Codes (DTC) from the Restraints Control Module (RCM) indicating an SRS wiring fault for one or more of the following reasons:
^ SRS wiring harness open circuit
^ SRS wiring harness short circuit
^ Air bag deployment during a vehicle collision which causes heat damage to an air bag connector.
Cause: SRS wiring harness damage or open circuit/short circuit condition.
Action: In the event a DTC from the RCM indicates an SRS wiring fault, refer to the Workshop Manual Service Procedure detailed in this bulletin to identify and replace the problem harness section with the appropriate overlay repair harness.
CAUTION: The firing circuit wiring between the air bags and RCM must not be repaired under any circumstances and must be replaced using the overlay harnesses described below. If an air bag has been deployed, the wiring harness that connects directly to the air bag MUST be replaced at the same time as the deployed air bag.
If a seat belt pretensioner has been deployed, replace this component only.
In case of the driver's air bag deployment, the "clock-spring" spiral connector MUST be replaced at the same time as the deployed air bag, but it is not necessary to replace the harness from the clock-spring to the fascia/body harness connector.
CAUTION: Where an air bag has deployed, the SRS overlay harness sections associated to the deployed air bag MUST be installed.
PARTS:
NOTE: RCM connector part numbers have changed during production. RCM connectors C3224 and C3223 were superseded by C3224L and C3223L, respectively. Reference should be made to GTR Electrical Circuit Diagram according to the vehicle MY and VIN.
TOOLS:
* YRW500030.............Wiring connector anti- back out device removal tool used on connectors C0067, C0083, C0231 & C0229; part of wiring harness repair kit.
*YRW900010.............Wiring connector anti- back out device removal tool used on connectors *C3224 & C3223*; part of wiring harness repair kit. (Figure 1)
YRW500070.............Wiring connector anti-back out device removal tool used on connectors C2368& C2378. Also used on ALL connectors as a wiring connector terminal delatch tool; part of wiring harness repair kit. (Figure 2)
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.
Normal warranty policy and procedures apply.
SERVICE INFORMATION
NOTES: GTR Workshop Manual does not yet contain overlay harness installation instructions.
^ Any harness replacement following accident related damage IS NOT claimable under warranty.
^ Refer to the relevant electrical circuit diagrams and electrical library to determine the harness section to be ordered to complete the repair.
^ Installation of driver and passenger overlays will require removal of the fascia. For further information refer to the relevant section in Global Technical Reference (GTR).
^ Replacement of all other overlays may require removal of some interior trim for access. For further information refer to the relevant section in Global Technical Reference (GTR).
^ The routing of the overlay harness MUST follow the routing of the original harness exactly while being secured by proper electrical tape or cable ties at regular intervals.
^ Always start securing the overlay harness from the point closest to the air bag and route towards the Restraints Control Module (RCM). In some cases the wiring will be longer than required as the overlay harnesses are designed to be used on left-hand and right-hand drive vehicles. Any surplus MUST be coiled and secured to the harness in the vicinity of the RCM or the body-to-fascia harness connector.
^ All DTCs should be cleared after repair using WDS/IDS.
* NOTE: Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > Service Information/ LA - LR3 > Workshop Manuals > Bookmark "General Information" link to "Standard Workshop Practices" section "Supplementary Restraint System (SRS) Precautions"
WARNING: All WARNINGS, CAUTIONS and precautions outlined under the Supplementary Restraint System (SRS) Precautions section, located in the Standard Workshop Practices section of GTR, must be followed.*
1. Refer to the attached Workshop Manual extracts for guidance with specific overlay harness installations until GTR is updated.
2. When harness repairs are completed initiate a diagnostic session and clear all DTC using WDS/IDS.
Service Procedure
Fascia Air bag Overlay
WARNING: The safety in the Workshop Manual supplementary restraint must be adhered to.
1. Remove the instrument additional information, Reference (GTR) Range Manual Section 501-12, Section (76.46.04).
2. Disconnect the bag.
3. Cut away the redundant old connector:
a. Secure the redundant with suitable electrical
4. Connect the overlay relevant air bag
5. CAUTION: Make sure the harness is not trapped installation.
Secure the new overlay wiring harness and follow the original back to the connector located in the
6. Disconnect the SRS connector.
7. Cut away and discard the
8. Secure the redundant harness with suitable
9. Connect the new overlay the fascia/body harness
10. Install the instrument additional information, Reference (GTR) Range Workshop Manual Section Panel Upper Section (76
Service Procedure
Body Air bag Overlay
WARNING: The safety precautions detailed in the workshop Manual to relating to supplementary restraint systems (SRS) must be adhered to.
NOTE: This overlay harness installation procedure is rationalized to reduce the number of repair times and the time provided is removal necessary for a D upper section. For harness repair. The refer to Global Technical renewals to all other Sport Workshop the parts required section
1. Disconnect the battery ground cable. For additional information, refer to Global Technical Reference(GTR) Range Rover Sport Workshop Manual Section 414-00, Specifications - Battery DIsconnect/Connect.
2. Make the SRS system safe.For additional information,refer to Global Technical Reference (GTR) Range Rover Sport Workshop Manual Section100-00,Standard Workshop Practices.
3. Disconnect the electrical connector from the air bag.
4. Remove interior trim as necessary to gain access to the relevant air bag connector and to follow the original wiring harness route exactly.
5. Cut away the redundant wire and discard the old connector:
a. Secure the redundant with suitable electrical tape.
6. Connect the overlay harness connector to rear air bag electrical connector.
7. CAUTION: Make sure the electrical harness is not trapped installation.
Secure the new overlay wiring harness to the existing wiring harness and follow exactly the route of the original back to the RCM.
8. WARNING: Ensure that only one wire is removed from the connector at a time to ensure that the replacement is located in the correct cavity. Refer to relevant wiring diagram in the electrical library where necessary.
Release the redundant wires from the RCM electrical connector:
a. Disconnect the electrical connector from the RCM.
b. Using special tool YRW900010, remove the red terminal anti-backout device.
c. Using special tool YRW500070, release the terminal latch and withdraw the terminal as shown below.
d. Cut the redundant wire approximately 5mm from the main harness and discard.
e. Secure the redundant wires to the harness with suitable electrical tape.
9. For renewal of seat air bag harnesses, the new overlay harness should be secured to the existing wiring harness and follow exactly the route of the original back to the seat connector.
a. Disconnect the seat electrical connector.
b. Using special tool YRW500070, remove the terminal anti-backout device.
c. Using special tool YRW500070, release the terminal latch and withdraw the terminal as shown.
d. Cut the redundant wire approximately 5mm from the main harness and discard.
e. Secure the redundant wires to the harness with suitable electrical tape.
10. CAUTION: Ensure the new terminal is correctly inserted into the connector and is secure.
Insert the correct wire from the overlay harness into the correct cavity of the connector.
11. Install the connector anti-backout device and install the connector.
12. Install removed interior trim as necessary.
13. Connect the battery ground cable. For additional information, refer to Global Technical Reference (GTR) Range Rover Sport Workshop Manual Section 414-00,
Specifications - Battery Disconnect/Connect.
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