Wiring Harness (G1823735)

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Use the table below to identify the type of wiring harness or section.

Repairs

2.0 General procedures

The following procedures should be followed for all harness repairs.

2.01 Approved probing and repair methods

The purpose of this document is to identify the approved methods to promote an effective and efficient diagnosis and minor repair to the:

• Permitted electrical wiring harnesses, connectors and cables
  • See Electrical Wiring Harness Repair - section 4.1
• Media Oriented System Transport (MOST) network harnesses, connectors and fiber optic cables
  • See MOST Network Harness Repair - section 2.13.

2.02 Replacement Repair Equipment

The repair processes in the following information identifies specific repair equipment needed to complete a repair to the required standard.

Replacement repair equipment can be ordered from the equipment workshop website:

http://jlrequipment.service-solutions.com

2.1 Twisted wire harnesses

It is important to make sure that the number of turns over the repair length is counted at the start of the repair. Make sure that the same number of turns are reintroduced before fitting the terminals into the connector. If the original number of turns cannot be reintroduced on a twisted wire, the following dimensions must not be exceeded.

It is important to maintain the correct number of twists per meter. It is suggested that the number of twists are counted over a set length. For example, if there are 50 twists/m, count the number of twists over 10cm (3.94 inches) of a representative section of the cable. This is to confirm that the number of twists is enough.

For a cable that has 50 twists/m, each twist is taking 2 cm (0.79 inches). Therefore, in 10 cm there will be at least 5 complete twists to consider that the twisting is acceptable. It is also important to compare the rest of the cable to confirm it visually has the same twisting.

The length of an untwisted part of a harness includes both ends. The image below shows untwisted sections and an indication of 1 twist.

2.1.1 Controller Area Network

The following details the repairs for a CAN harness. The CAN has twisted wires.

For aCAN harness, the maximum length of untwisted wire is 150 mm (5.9 inch).

Follow the repair procedure as in section 4 of this document.

2.1.2 FlexRay

The following details the repairs for a FlexRay harness. The FlexRay has twisted wires.

For a FlexRay harness, the maximum length of untwisted wire is 60 mm (2.3 inch).

Follow the repair procedure as in section 4 of this document.

2.1.3 BroadR-Reach®

The following details the repairs for a BroadR-Reach® harness. The BroadR-Reach® has twisted wires.

For a BroadR-Reach® harness, the maximum length of untwisted wire is 50 mm (2.0 inch).

Follow the repair procedure as in section 4 of this document.

2.2 Radio Frequency harness

Follow the repair procedure as in section 4 of this document.

2.3 Local Interconnect Network bus

Follow the repair procedure as in section 4 of this document.

2.4 Co-axial

Usually a connection from an antenna to an antenna amplifier.

Follow the repair procedure as in section 4 of this document.

2.5 National Television System Committee

National Television System Committee (NTSC) is a video standard for NAS vehicles

Follow the repair procedure as in section 4 of this document.

2.6 Low Voltage Differential Signal

Low Voltage Differential Signal (LVDS) is a video signal for ROW vehicles.

Follow the repair procedure as in section 4 of this document.

2.7 Serial communication

Follow the repair procedure as in section 4 of this document.

2.8 Pulse Width Modulation

Follow the repair procedure as in section 4 of this document.

2.9 Universal Serial Bus

Follow the repair procedure as in section 4 of this document.

2.10 Automotive Pixel Link 2

Audio/video connection. APIX2 is used for signals between the Infotainment system and the Instrument Panel Cluster Control Module (IPC) and Head Up Display (HUD).

Follow the repair procedure as in section 4 of this document.

2.11 High Voltage Interlock Loop

A safety system in EV and Plug-in Hybrid Electric Vehicle (PHEV). prevents the system being powered up if a HV cable or harness is disconnected.

Follow the repair procedure as in section 4 of this document.

2.12 Battery Monitoring System Fusible Link

The BMS fusible link must be replaced, repairs are not to be performed on the fusible link.

If the fusible link ruptures then the source of the fault must be diagnosed and rectified first. The fusible link is then to be replaced using the authorized service repair kit (part number LR057241). The fusible link must be spliced into the affected lead/circuit using the approved sealed inline splice repair technique. See section 4 wire only repair procedure.

Refer to the Electronic Parts Catalogue (EPC) for available components. Stock check required.

2.13 Media Oriented System Transport Network Harness Repair

The MOST connector(s) have an anti-backout device which prevents the contact from being released from the connector. The anti-backout device must be released before attempting to remove the terminal from the connector. The anti-backout devices require a special tip to release the device. Please refer to the Electrical Reference Library (ERL) for the correct tool(s) to use.

The illustration shows an example of a common style of extraction tool being used on a MOST connector(s). Care should be exercised to avoid further damage when removing the terminals from the connector.

If a fiber optic cable is damaged, it must not be repaired and must be replaced with a new cable.

Replacement fiber optic cables can only be made using the approved repair equipment and components.

The approved repair kit contains the specially designed fiber optic conductor strippers. The cutters are used to prepare 2.3 mm (0.09 inch) fiber optic cable for the installation of the brass fiber optic conductor contact. The fiber optic conductor contact crimping pliers must then used be used to crimp the brass contact to the fiber optic conductor core. The approved crimping pliers supply the appropriate pressure to the brass contact to make a secure contact, but not damage the conductor core.

The cut face of the fiber optic core must be protected from damage and contamination at all times.

The performance of fiber optic cables is very dependant upon the quality of the cut surface at connections and to the bending radius of the cables.

2.13.2 MOST Harness Repair Components and Tools

List of Parts

The fiber optic core cutter has a locking screw to protect the cutter wheel when in transit or not in use. A hexagonal key is supplied in the MOST repair kit to release the locking screw.

The fiber optic core cutter can be used for approximately 1260 cuts. The indicator line on the remaining cut indicator window only becomes visible when the fiber optic core cutter has 150 cuts or below available.

Before using the fiber optic conductor core cutter, make sure it has enough cuts remaining to complete the repair process by viewing the remaining cut indicator.

A small amount of effort is required to operate the fiber optic conductor contact crimping pliers and secure a fiber optic conductor contact to the fiber optic conductor core.

The new fiber optic conductor contact is placed into the cramping mechanism in the head of the pliers. The locking arm is repositioned to hold the conductor contact securely in position. The locking arm must locate on to the retaining pin.

The prepared end of the fiber optic core is then inserted into the new conductor contact.

The fiber optic core and conductor contact must be pushed and held against the spring pressure in the cramping mechanism. The grips of the fiber optic conductor contact crimping pliers are then be closed, cramping the conductor contact to the conductor core.

The cramping mechanism inside the head applies the appropriate pressure to the conductor contact at 4 points. This makes a secure contact and does not damage the conductor core.

When the new conductor contact has been cramped to the fiber optic core do the following. Make sure the fiber optic core end sits 0.01 mm (0.00039 inch) to 0.1 mm (0.0039 inch) below the height of the conductor contact end.

MOST Repair Tools

2.13.3 MOST Harness Repair Procedure

The MOST connector(s) have an anti-backout device which prevents the contact from being released from the connector. The anti-backout device must be released before attempting to remove the terminal from the connector. The anti-backout devices require a special tip to release the device. Please refer to the ERL for the correct tool(s) to use.

The illustration shows an example of a common style of extraction tool being used on a MOST connector(s). Care should be exercised to avoid further damage when removing the terminals from the connector.

2.14 Air suspension overlay

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 Workshop manual section 414-00, Specifications - Battery Disconnect/Connect.

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.

5. Cut the wire on the vehicle harness leading to cavity 1 of the height sensor connector in a suitable position. Then remove 10 mm (0.39 inch) of insulation. For connector location and pin identification, refer to the relevant connector:

• L320 - C1696/7/8/9
• L405/L494 - C1CD10/11/12/13

In the Connector Details section of the relevant Electrical Library.

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.

8. Select the appropriate wire on the overlay harness that also goes to cavity 1 of the new connector. Cut the wire to the correct length and remove 10 mm (0.39 inch) of insulation.

9. Insert the overlay wire into the connector and crimp in place.

10. Slide the heatshrink over the connector and using a hot air applicator carefully apply the heat until the glue appears at both ends.

11. Do the same process for the wires in cavities 4 and 5 of the connector. For connector location and pin identification, refer to the relevant connector:

• L320 - C1696/7/8/9
• L405/L494 - C1CD10/11/12/13

In the Connector Details section of the relevant Electrical Library.

12. Discard the damaged connector/section of the harness.

13. Add suitable harness repair tape to the repaired area to within 10 mm (0.39 inch) 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 Workshop manual section 414-00, Specifications - Battery Disconnect/Connect.

16. Clear any Diagnostic Trouble Codes (DTC) set in the Chassis Control Module (CHCM) using JLR approved diagnostic equipment and confirm correct operation of the system.

2.15 Supplementary Restraint System

The wiring used for a SRS firing circuit repair must be 0.5 mm² (0.00078 inch²) cross sectional area. Replace Both the affected male and female terminals in the connector using pre-terminated leads. Installation of SRS connectors, cut the wiring harness at a suitable point as close as possible to the damaged connector (destroy the removed connector). Identify the correct new connector from the SRS firing circuit wiring harness repair kit or recommended overlay and cut to a suitable length. Install to the SRS firing circuit wiring harness using the connecting splices supplied and a replaced pre-terminated lead which can be identified from the ERL wire chart information.

Follow the repair procedure detailed above, taking into account the staggering of connecting splices and the number of twists. The whole repair should then be covered with yellow heat shrink sleeve supplied to act as SRS firing circuit wiring repair location/identification. The repair authentication label must be completed by the authorized technician conducting the repair and approved by their supervisor. The label must then be secured around the harness adjacent to or at a suitable point as close as possible to the location of the repair.

Care and neatness are essential requirements in making a perfect repair.

2.16 12V Mild Hybrid Electric Vehicle

Follow the repair procedure as in section 4 of this document.

2.17 Low Voltage 3 Phase

Follow the repair procedure as in section 4 of this document.

2.18 High Voltage cables and harnesses

Currently there are no repairs allowed to the HV cables and harnesses. These cables and harnesses have an ORANGE covering.

If a HV battery cable or harness is damaged, it must be replaced, not repaired.

2.19 Mild Hybrid Electric Vehicle

Currently there are no repairs allowed to the MHEV cables and harnesses. These cables and harnesses have an LIGHT BLUE covering.

If a 48V MHEV battery cable or harness is damaged, it must be replaced, not repaired.

3.1 Electrical connector probing

The following sections identify the approved method for electrical connector probing.

3.11 Electrical Connector Probing

Only 2 methods of electrical connector probing are allowed.

Method 1. Probing at the rear of unsealed electrical connectors (see illustration E190832).

Method 2. Probing on the conductor crimp of an extracted terminal (see illustration E190928).

• The conductor crimp is the portion crimped to the non-insulated wire.
• This method may be used on sealed or unsealed connectors, but method 1 is preferred for unsealed connectors.

The following 2 methods of electrical connector probing are not allowed.

Method 1. Probing at the rear of sealed electrical connectors (see illustration E190926).

Method 2. Probing at the electrical connector contact area (see illustration E190927).

3.12 Live Probing on Sealed Connectors

1. Disconnect the battery ground cable.
2. CAUTION:

   Before extracting any terminals, refer to the Electrical Connector Terminal Extraction and Extraction Tools sections of this document for more information.

   Extract the terminal to be tested from the electrical connector
3. Insert a substitute wire with the same terminal and cross sectional area of the previously extracted wire, into the vacated position of the electrical connector.
4. CAUTION:

   The link lead clip must only be attached to the portion of the extracted terminal that is crimped directly to the section of non-insulated wire.

   Attach 1 end of the link lead to the original wire terminal.
5. CAUTION:

   The link lead clip must only be attached to the non-insulated section of the wire.

   Attach the remaining end of the link lead to the substitute wire.
6. Reconnect the electrical connector.
7. Reconnect the battery ground cable and begin the test.

3.2 Pin Drag Test

This is not allowed.

3.3 Grommets

Grommets - repair/replacement and additional circuits

Solid (over moulded) grommets are non-repairable and must be replaced by the installation of a new harness. Grommets with plastic inserts for panel retention – the inserts can be removed and replaced where necessary.

EPDM (Rubber) grommets: if the grommet is damaged then a 1 off attempt to repair with a suitable automotive grade silicon sealant is allowed. When the repair is completed, test for leaks (noise/fumes/water). If this fails to seal then the harness must be replaced.

If any vehicle accessories are added that require additional wires/circuits to pass through a sealed grommet then these must be routed through the service nipple. The service nipple must then be sealed using a suitable automotive grade silicon sealant and secured as shown below.

3.4 Harness/cable clips

Clip/Fixing repair/replacement

The following applies to 12V applications

When doing any Electrical Distribution System (EDS) repairs or investigating vehicle faults/failures the following guidelines must be followed:

• Broken clips and fixings must be replaced
• Damaged/worn clips and fixings that could fail in service must be replaced
• When a harness is removed to facilitate vehicle/powertrain strip down it may compromise the retention performance of some clips/fixing types. Any clip/fixing that is used in an area subject to dynamic movement or high vibration whose retention features were damaged by removal during strip down must be replaced.

The majority of clips/fixings are listed in the following table.

Push old or damaged fixing out of the way (turning it around the harness if necessary) and put on new fixing. Inspect fixing positioning to make sure that the harness is not close to anything hot, sharp or dynamic.

The following applies to 48V MHEV and HV applications.

All HV fixings are classified as ‘critical’ for the vehicle assembly process. Threaded fixings must be reassembled using the specified torque (published in the Work Shop Manual/Topix). For all HV fixings, wherever possible the damaged part is to be displaced/pushed out of the way. The damaged part must be left in place and the new part installed alongside in the exact location of the old/previous fixing. Where the fixing must be removed to facilitate replacement then extreme care must be used to prevent risk of damage to the cables and coverings

4.1 APPROVED ELECTRICAL WIRING HARNESS REPAIR METHODS

It is necessary to identify:

• The conductor (wire) size of the affected wiring harness
• The electrical connector range from which the damaged wiring harness is to be removed
• The electrical terminal type

Use of the JLR approved diagnostic equipment will greatly assist in the quick identification of electrical connectors and damaged pin terminal(s).

Reference can also be made to the ERL and Interactive Electrical Wiring Diagrams (iEWD) available through TOPIx, to identify wiring harness(s) and electrical connector(s).

Use the Electrical Wiring Harness Repair Relationship Table to identify the correct splice connector to suit the wiring harness conductor (wire) size. This will relate to a suitable pre-terminated lead by the color of the insulation. The table also identifies the correct length of insulation to be stripped from the wiring harness lead.

Electrical Wiring Harness Repair Relationship Table

Various types of electrical connector have seals installed internally or externally to prevent moisture ingress. These normally do not have to be removed but make sure that they are installed when the electrical connectors are connected.

The illustrations show examples of some of the common styles of extraction tools used on different types of electrical connector(s). Care should be exercised to avoid further damage when removing the terminals from the electrical connector.

4.2 Types of Electrical Wiring Harness Splice Repairs

Splice connectors are available in 3 sizes; refer to Pre-Terminated Lead and Splice Connectors in the Electrical Wiring Harness Repair Components section.

A splice connector can be used in a number of ways to achieve an effective and robust wiring harness repair.

The following information will show and explain the variations of splice joints achievable; these are:

• A 1 Wire Splice Repair
• A 2 Wire Splice Repair
• Pulled Out Wire Splice Repair
• Damaged Splice Repair
• Double Splice Extension Repair
• Splice Repair to Wire Smaller than 0.35 mm² (0.00054 inch²)

1. Original Wire
2. Original Wire
3. Splice Connector
4. Glue Lined Heat Shrink Sleeve

If the wiring harness has a damaged eyelet with 2 wires to the eyelet, it is recommended to use a suitable pre-terminated lead. The lead should have a cross sectional area equal to or greater than that of the 2 wires combined to complete the repair.

1. Pre-terminated Lead
2. Original Wire
3. Original Wire
4. Splice Connector
5. Glue Lined Heat Shrink Sleeve

Cut the undamaged wire of the original splice and with a suitable splice connector, clamp the splice side of the wire. Install a suitable section of glue lined heat shrink sleeve to the splice the wire had disconnected from. Insert the disconnected wire and the undamaged wire into the splice connector and clamp the splice connector.

1. Original Splice
2. Glue Lined Heat Shrink Sleeve
3. Original Undamaged Wire
4. Pulled Out Wire
5. Original Undamaged Wire
6. Splice Connector
7. Glue Lined Heat Shrink Sleeve

Remove the damaged splice by cutting it from the wiring harness, making sure to leave as much undamaged wire as possible on the wiring harness. Using 1 or more suitable splice connectors make a new splice.

1. Original Wire
2. Original Wire
3. Original Wire
4. Original Wire
5. Splice Connector
6. Glue Lined Heat Shrink Sleeve

The extension wire must have the same or greater cross sectional area as the wire(s) combinations entering the splice connectors. Example: 2 wires x 0.5 mm² (0.00077 inch²) cross sectional area + 2 wires x 0.75 mm² (0.0012 inch²) cross sectional area would require a wire of 2.5 mm² (0.0039 inch²) cross sectional area or greater.

1. Original Wire(s)
2. Original Wire(s)
3. Extension Wire
4. Splice Connector
5. Glue Lined Heat Shrink Sleeve
6. Splice Connector
7. Glue Lined Heat Shrink Sleeve

For each splice repair to a wire smaller than 0.35 mm² (0.00054 inch²), an additional piece of wire (0.35 mm² (0.00054 inch²) or 0.5 mm² (0.00078 inch²)) must be used. The additional piece of wire must be inserted into the splice connector with the wire being repaired. to make the joint secure when crimped. When the wires have been crimped into the splice connector, all additional wire(s) must be cut close to the splice connector. This is to make sure the additional wire is fully covered when the glue lined heat shrink sleeve is in position over the splice connector.

1. Original Wire (less than 0.35 mm² (0.00054 inch²))
2. Additional wire (0.35 mm² (0.00054 inch²) or 0.5 mm² (0.00078 inch²))
3. Pre-terminated Lead or replacement wire (less than 0.35 mm² (0.00054 inch²))
4. Additional wire (0.35 mm² (0.00054 inch²) or 0.5 mm² (0.00078 inch²))
5. Splice Connector
6. Glue Lined Heat Shrink Sleeve

Repairs to twisted wires

See the individual repair procedure for twisted wire harnesses.

4.3 Wiring Harness Repair Procedure

Before starting any repair of a damaged wire, the damaged wire must be inspected along its length where possible to evaluate the full extent of the damage. If the damage is in a localized area the wire repair is recommended, if the damage is extensive, a replacement harness should be considered. A wire being repaired must be cut at a point where there is no damage to the wire or insulation.

Where there is a need to repair more than 1 wire in a harness branch, the splices must be staggered. This will minimize the effect of increasing the diameter of the harness branch. The recommended spacing is 50 mm (2.0 inch) between centers for yellow splices and 40 mm (1.57 inch²) between centers for red or blue splices.

There is no specific limit on the number of splices that can be used in a harness branch. The responsible technician must judge the number of splices that can be installed along the available length of harness and within the space in which the harness is located.

Consideration must be given to any need to bend the harness and the risks of the repaired harness rubbing, squeaking or rattling against adjacent parts, body panels or trim.

Wiring Harness Repair Process

1. Remove the damaged terminal from the electrical connector using the correct extraction tool. Make sure that any anti-backout device is released before trying to remove the terminal.
2. CAUTION:

   A number of electrical connector terminals are gold plated or gold flashed. When damaged, they must be installed with a gold pre-terminated wiring harness(s). It is not always easy to identify the female as gold but the male pins are visually easier. Therefore always inspect both male and female terminals to identify those which are gold. Under no circumstances are gold and tin terminals to be mixed as this will lead to early failure of the electrical contact.

   NOTE:

   Never use a harness lead with a smaller diameter than the original harness lead.

   Select the correct size and type of pre-terminated wiring lead and splice connector; refer to Wire Chart and Service Repair Information.
3. Using the wire cutter on the insulation (wire) stripper, cut the pre-terminated wiring harness and the harness cable to the required length.
4. NOTE:

   See illustration: Stripping Insulation

   From the Electrical Wiring Harness Repair Relationship Table, find the correct length of insulation to be stripped from the pre-terminated lead. Set the adjustable cable length stop to the correct length. Place the pre-terminated lead in the insulation (wire) stripper and remove the insulation.
5. Put the cable identification sleeve(s) on to the wiring harness with the main cable color nearest to the terminal.
6. During this next step take care only to close the crimpers far enough to hold the splice connector firmly in position. Place the selected splice connector in the crimpers, matching the aperture and the splice connector colors. Make sure that the window indentation in the splice connector is resting over the guide bar on the lower jaw. Partially close the grip until the splice connector is securely held in the aperture. This will give support to the splice connector while the wiring harness(s) are inserted into it.
7. NOTE:

   See illustration: Splice Correctly Located

   Insert the pre-terminated lead into the splice connector and make sure that the wire is against the wire stop. Close the grip firmly, crimping the pre-terminated lead to the splice connector. When the handles have been completely closed the splice connector will be freed from the tool as the handles are released. If the handles have not been completely closed then the jaws will hold the splice connector and it cannot be removed from the tool.
8. Make sure that the wiring harness cable has been squarely cut and the correct length of insulation removed. If more than 1 splice is needed the splice connectors must be not be crimped to the wiring harness at the same distance from the connector. The splices must be staggered to prevent a bulk of splices in the same area of the wiring harness.
9. It is preferable to cover the splice joint with a glue lined heat shrink sleeve. This is desirable not essential, except where the electrical connector is a sealed electrical connector. Use the smaller diameter glue lined heat shrink sleeve for red and blue pre-terminated lead(s). Use the large diameter glue lined heat shrink sleeve for the yellow pre-terminated lead(s). It is advisable to place the heat shrink sleeve over the completed joint but in some instances the glue lined heat shrink sleeve will not pass over the terminal. Inspect, and if required, place the correct size glue lined heat shrink sleeve onto the harness cable or pre-terminated lead before crimping the splice to the wiring harness.
10. Place the harness cable into the splice with the splice window over the guide bar. Make sure that the harness cable is against the stop in the splice, crimp the splice connector to the wiring harness.
11. Gently pull the harness cables each side of the splice connector to make sure that a secure joint has been made.
12. WARNING:

    Do not use a naked flame in areas where fuel or oil have been spilt. Clean the area of residual oil and fuel and wait until the fuel spill has fully evaporated.

    CAUTIONS:

    • When using a heat source make sure that it is localized and causes no damage to surrounding materials.

    • Where the repair procedure indicates that a glue lined heat shrink sleeve should be applied, apply sufficient heat to the glue lined heat shrink sleeve. This will melt the glue in order to provide a water tight seal. Do not over heat the glue lined heat shrink sleeve so that the wiring harness insulation becomes damaged.

    Using a suitable heat source, shrink the sleeve over the splice.
13. If further pre-terminated lead(s) are to be installed to the same electrical connector, make sure that the lead is cut at a different length to the previous joint. This makes sure that the splices will, where possible, be staggered on the wiring harness and prevent a bulk of splices in 1 area.
14. When all of the splices have been made, install the terminal(s) to the electrical connector, taking care that the terminals are correctly oriented.
15. Install the wiring harness cover and secure with adhesive electrical tape. Do not cover the wiring harness right to the electrical connector. The terminals must have a little movement and not be firmly bound to the electrical connector or wiring harness. Make sure that the cable identification sleeve(s) are showing at the wiring harness electrical connector.

4.4 Electrical Wiring Harness Repair Components

The electrical wiring harness repair components comprises of:

• Pre-terminated leads of different sizes and types
• Splice connectors in 3 sizes
• A selection of colored cable identification sleeves
• Glue lined heat shrink sleeves in 2 sizes.

The pre-insulated diamond grip range of electrical connector terminals and in-line splice connectors are the only acceptable product for the repairs of wiring harnesses. The splice connectors not only grip the wire but also the insulation, making a very secure joint.

Splice connectors are also supplied with red, blue or yellow coverings, which must be matched to the pre-terminated lead insulation color.

For ease and speed, some of the pre-terminated lead(s) may already have the insulation partly stripped at the splice end. If the repair requires insulation to be stripped from the cable, refer to the Electrical Wiring Harness Repair Relationship Table in the Repair Methods section. The correct length of insulation to be stripped will be detailed in the table.

When the relevant connector housing has been identified, refer to the associated Wire Chart and Service Repair Information. This is to make sure the installation of pre-terminated leads or wiring harnesses are completed in the approved manner.

• Identify the connector cavity in which the terminal needs replacing
• Make a note of the cross sectional area of the associated wire
• Make a note of the part number of the appropriate pre-terminated lead
• Make a note of the correct terminal extraction tool (where applicable)

Before commencing a wiring harness repair, always make sure the correct pre-terminated leads and associated repair parts have been ordered using the JLR parts ordering system.

Some of the pre-terminated leads have seals installed to the insulation for sealed connector applications. Where, as part of a repair, sealed terminals are removed, it is essential that those terminals are replaced by sealed pre-terminated leads.

Wire chart and service repair information also includes:

• The destination of the cable
• The applicable tools and associated other parts necessary to make sure the pre-terminated lead is correctly installed in the approved manner

The sleeve identification packs are available to suit the 3 cable size ranges of Red, Blue and Yellow. Each sleeve identification pack contains 50 of each of the following colored sleeves:

• Black
• Brown
• Red
• Orange
• Yellow
• Green
• Blue
• Violet
• Gray
• White

Place the correct colored sleeve(s) over the pre-terminated lead insulation as near to the electrical connector as possible. The main wiring harness cable color should be nearest to the electrical connector.

For example: if the original wiring harness cable color is green with a black trace:

Wiring Harness Repair Parts

4.5 Wiring Harnesses

The repair is only appropriate where the damage is localised and is not over the full length of the wiring harness. If the damage is end to end then replacing the whole harness should be considered where appropriate. The damaged section of wiring harness must be removed by cutting either side of the damage at a point where the wiring harness retains its original condition. The number of twists in a twisted pair of wires is important to the functionality of the circuit and as such must be maintained. Note the number of twist over the repair length prior to commencing the repair. The same number of twists must reintroduced after completing the repair.

If repairing multiple wires within a harness, stagger the connecting splices and twist the wire between the connecting splice locations. This will minimize the untwisted length and the effect of increasing the diameter of the harness. On no account must the untwisted length exceed 50 mm (2.0 inch) each side of the connecting splice. When each connecting splice repair is completed, cover the splice with a black glue lined heat shrink sleeve. Use an approved hot air applicator to shrink the sleeve until the glue is visible at both ends. Make sure that connecting splice repairs are not located in any dynamic movement area of a harness.

When all wiring harness repairs are complete, the wiring harness must be wrapped in insulating tape and returned as close as possible to new vehicle condition. Make sure the wiring harness follows the original routing and all clips and connectors are secured.

If any harness(s) with damaged electrical connector terminals or cables from the above circuits give cause for concern, new components must be installed.

If any harness(s) with damaged electrical connector terminals or cables from the above circuits give cause for concern, new components must be installed.

4.5.1 Electrical Wiring Harness Repair Components

The electrical wiring harness repair components comprises of:

• Pre-terminated leads of different sizes and types
• Splice connectors in 3 sizes
• A selection of colored cable identification sleeves
• Glue lined heat shrink sleeves in 2 sizes.

The pre-insulated diamond grip range of electrical connector terminals and in-line splice connectors are the only acceptable product for the repairs of wiring harnesses. The splice connectors not only grip the wire but also the insulation, making a very secure joint.

Splice connectors are also supplied with red, blue or yellow coverings, which must be matched to the pre-terminated lead insulation color.

For ease and speed, some of the pre-terminated lead(s) may already have the insulation partly stripped at the splice end. If the repair requires insulation to be stripped from the cable, refer to the Electrical Wiring Harness Repair Relationship Table in the Repair Methods section. The correct length of insulation to be stripped will be detailed in the table.

When the relevant connector housing has been identified, refer to the associated Wire Chart and Service Repair Information. This is to make sure the installation of pre-terminated leads or wiring harnesses are completed in the approved manner.

• Identify the connector cavity in which the terminal needs replacing
• Make a note of the cross sectional area of the associated wire
• Make a note of the part number of the appropriate pre-terminated lead
• Make a note of the correct terminal extraction tool (where applicable)

Before commencing a wiring harness repair, always make sure the correct pre-terminated leads and associated repair parts have been ordered using the JLR parts ordering system.

Some of the pre-terminated leads have seals installed to the insulation for sealed connector applications. Where, as part of a repair, sealed terminals are removed, it is essential that those terminals are replaced by sealed pre-terminated leads.

Wire chart and service repair information also includes:

• The destination of the cable
• The applicable tools and associated other parts necessary to make sure the pre-terminated lead is correctly installed in the approved manner

The sleeve identification packs are available to suit the 3 cable size ranges of Red, Blue and Yellow. Each sleeve identification pack contains 50 of each of the following colored sleeves:

• Black
• Brown
• Red
• Orange
• Yellow
• Green
• Blue
• Violet
• Gray
• White

Place the correct colored sleeve(s) over the pre-terminated lead insulation as near to the electrical connector as possible. The main wiring harness cable color should be nearest to the electrical connector.

For example: if the original wiring harness cable color is green with a black trace:

Wiring Harness Repair Parts

4.5.2 Wiring Harness Repair Tools

The wiring harness repair tools comprises of:

• A selection of extraction tools
• A wire cutter and insulation stripper
• Crimpers

The adjuster has a position indicator to align with a graduated scale and this sets the correct length in millimeters, of insulation to be stripped. The amount of insulation to be stripped is shown in the Electrical Wiring Harness Repair Relationship Table.

The following illustration shows the insulation stripper tool and a wiring harness correctly gripped in the jaws. A wire cutter is provided on the outer side of the fixed jaw.