Canada - Suspension - New Height Sensor And Harness

Bulletin
2431

Issue Date
June 18, 2007

Title
HEIGHT SENSOR & REAR HARNESS IMPROVEMENT

Component
BODY ELECTRICAL

Models
'03 - '07 LX 470

INTRODUCTION:

To improve salt and corrosion prevention, new and improved front and rear height sensors and a rear height sensor sub-wiring harness are now available.

APPLICABLE VEHICLES:
- 2003 - 2007 model year LX 470 vehicles produced BEFORE the Production Change Effective VINs shown below.






PRODUCTION CHANGE INFORMATION:






PARTS INFORMATION:






WARRANTY INFORMATION:






SUB-WIRING HARNESS KIT COMPONENTS:

REPAIR PROCEDURE:

Height Control Sensors Replacement:

1. Confirm customer condition of uneven ride height.
2. Remove and replace front and rear height sensors.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Lexus
- Model: LX 470
- Year: 2004 or 2005
- Service Category: Suspension
- Section: Suspension Control System
- Keyword: Height Control Sensor: Removal
- Keyword: Height Control Sensor: Installation

- Division: Lexus
- Model: LX 470
- Year: 2006 OR 2007
- Service Category: Suspension
- Section: Suspension Control System
- Keyword: Suspension Control: Height Control Sensor: Removal
- Keyword: Suspension Control Height Control Sensor: Installation

Rear Height Sensor Sub-wiring Harness Installation:

1. Secure and lift vehicle.
2. Remove both rear wheels and spare tire
3. Inspect the rear height sensor/wiring harness for corrosion (see the illustration in the Rear Sensor and Harness Inspection procedure in this TSB).
4. Install new rear height sensor sub-wiring harness (see New Rear Height Sensor Sub-wiring Harness Installation procedure in this TSB).
5. Reinstall rear wheel assemblies on vehicle.

Torque: 131.5 N-m (1341 kgf-cm, 97 lbf-ft)

6. Drive vehicle to confirm condition corrected.

Rear Sensor and Harness Inspection:

Inspect the rear height sensor terminal pins for corrosion.

If rear height sensor pins show evidence of corrosion and/or water entry into the rear height sensor connector, then install the NEW countermeasure sub-wiring harness for the rear height sensor.






Refer to the New Rear Height Sensor Sub-wiring Harness Installation procedure in this TSB.

New Rear Height Sensor Sub-wiring Harness Installation:

NOTE:
For more information on wire harness repair, refer to TIS, Wire Harness Repair.

1. Cut the existing rear height sensor harness.
A. Cut the wire harness that connects to the rear height sensor.






B. Pull the wires out of the corrugated tube.
C. Cut each of the 3 wires approximately 40 mm (1.57 in.) longer than the next wire (refer to the following illustration).






D. Cut the extra corrugated tube (refer to the illustration) away from the wires.

2. Strip the insulation from the wires on the existing harness and the NEW sub-wiring harness.






Strip at least 8 - 11 mm (0.31 - 0.43 in.) away from the end of the existing harness on the vehicle side and also from the end of the NEW sub-wiring harness.

3. Crimp the replacement terminal lead to the harness lead.






A. Overlap the two stripped wire ends inside the sleeve as shown in the illustration.





B. Place the sleeve in the correct section of the tool according to the color of the sleeve itself.
C. With the center of the sleeve correctly placed between the crimping jaws, squeeze the crimping tool until either end comes into contact at the section marked by "CLOSE HERE".






HINT:
Check to see that the sleeve and wires are still in the correct position before closing the crimping tool ends with steady pressure.

D. Pull the joined wires to either end. Make sure that they are joined firmly by the sleeve.






NOTE:
If the joined wires come loose, the splice is defective. Replace the sleeve and repeat the procedure.






E. Crimp both ends of the sleeve with the crimping tool at the "INS" position.










4. Wrap each crimped portion of the wires with water proof tape (supplied in the sub-wiring harness kit).






5. Wrap both ends of the water proof tape with vinyl tape.
6. Cover the 3 wires with corrugated tube.
A. Cover the water proof tape with corrugated tube (supplied in the sub-wiring harness kit).






B. Wrap the entire corrugated tube with the vinyl tape.

7. Install the wire harness clip to the sensor bracket.






8. Wrap up the extra wire harness with the tie wrap.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.