Air Suspension Overlay Harness Introduction

If after diagnosis the height sensor requires replacement and the area of wiring damage is localized to the height sensor connector, this overlay harness should be used,

1. Disconnect the battery ground cable. For additional information, refer to Battery Disconnect And Connect (G1033944) .
2. Disconnect the damaged height sensor electrical connector.
3. Unclip a sufficient length of the wiring harness to allow easy access during the repair.
4. Remove the wiring harness insulation as required.
   NOTE:

   • It is advisable to cut only one of the wires at a time and to stagger each joint to allow easier insulation.
   • The colours of the overlay harness may vary.
5. Cut the wire on the vehicle harness leading to cavity 1 of the height sensor connector in a suitable position and remove 10mm of insulation.
6. Slide over this wire a section of heat shrink sleeving.
7. Using the inline connector supplied and the correct crimping tool set to the correct jaw size from the harness repair kit, crimp the connector to the wire.
   NOTE: The overlay harness should be cut so that there is no additional length added to the overall length after repair.
8. Select the appropriate wire on the overlay harness that also goes to cavity 1 of the new connector, cut to the correct length and remove 10mm of insulation.
9. Insert the overlay wire into the connector and crimp in place.
   CAUTION: Care must be taken when using the heat gun to avoid damage to surrounding areas.
10. Slide the heatshrink over the connector and using a hot air gun carefully apply the heat until the glue appears at both ends.
11. Carry out the same process for the wires in cavities 4 and 5 of the connector.
12. Discard the damaged connector/section of the harness.
13. Add suitable harness repair tape to the repaired area to within 10mm of the new connector to complete the repair.
14. Correctly route/secure the harness and connect the new connector to the height sensor.
15. Connect the battery ground cable. For additional information, refer to Battery Disconnect And Connect (G1033944) .
16. Clear any Diagnostic Trouble Codes logged in the air suspension control module using Land Rover approved diagnostic equipment and confirm correct operation of the system.