2016 Land Rover Discovery Sport Wiring Harness Repair

We were contacted asked if we could supply and manufacture an engine wiring loom for a 2016 Land Rover Discovery Sport. We responded that without assembly diagrams, which we would not likely be able to access, it would require an original harness to reverse engineer and would be extremely expensive. We asked why they were looking for a wiring loom?

The customer told us the car had broken down 5 weeks ago and the garage diagnosing the fault with the vehicle had advised "The wiring loom needs to be replaced as one of the plugs for the gearbox is broken. Repairing the existing loom isn’t possible as finding the individual part would be difficult without a part number for the part that’s broken which they cannot get. Land Rover have 25 on back order and no fulfilment date"

This is fairly normal response for a typical garage as they usually won't have the same level of wiring knowledge as a wiring harness manufacturer like ourselves would have. As we have experience souring hard to find connectors, we asked for some photos of the connector and advised it was very likely we would be able to repair if we could identify and source the connector.

Now we could clearly see the damage and after some back and forth we managed to get a picture of part number off the connector body which led us to find the 58 pin TE MCON 1.2/2.8 Hybrid connector and missing lock. We some of the harness tape had been removed also so we had to advise the customer that there was some risk involved with the repair as there could be additional damaged sections. We would visually inspect the wiring but there could be other faults we could not see and we couldn't guarantee replacing the connector body would repair the vehicle.

The customer accepted the risk, we ordered the necessary parts and the customer sent their wiring harness to us. We had to carefully depin and repin a single wire at a time ensuring we took plenty of photos clearly showing each wire colour and its location.

Right at the end of the job when removing the larger terminals, we unfortunately damaged one of the locking tabs. Some new terminals were ordered to replace the damaged one and crimped with the correct Rennsteig crimp tool.

Within 16 days of arriving with us the wiring loom was repaired and send out for a fraction of the cost of a new harness from Land Rover which was on backorder with no date of arrival.