Wiring Harness Repair Procedure: Notes
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.
- If the wire repair requires the use of a pre-terminated lead, the wire must not be cut more than 300mm from a connector housing.
- A repaired wire must not be under any strain when connected to its intended component/connector housing.
Where there is a need to repair more than one wire in a harness branch, the splices must be staggered to minimize the effect of increasing the diameter of the harness branch. The recommended spacing is 50mm between centers for yellow splices and 40mm between centers for red or blue splices.
- Do not use crimpers, insulation (wire) strippers, splice connectors, heat shrink sleeves or pre-terminated leads or wiring harness(s) that are not authorized and supplied via the Jaguar/Land Rover parts ordering system. Each part has been designed to be used only with the other parts available via the Jaguar/Land Rover parts ordering system.
- 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 to 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.
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 fitted 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.