Electrical Wiring Harness Repair Components

The electrical wiring harness repair components comprises of:

1. Pre-terminated leads of different sizes and types
2. Splice connectors in 3 sizes
3. A selection of colored cable identification sleeves
4. 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.

Pre-Terminated Lead and Splice Connectors 

The pre-terminated lead(s) are supplied with the insulation in 1 of 3 colors, red, blue or yellow. The colors indicate the cable size range and not any particular circuit; refer to Electrical Wiring Harness Repair Relationship Table 

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 Electrical Wiring Harness Repair Relationship Table  The correct length of insulation to be stripped will be detailed in the table.

Wire Chart and Service Repair Information 

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.

1. Identify the connector cavity in which the terminal needs replacing
2. Make a note of the cross sectional area of the associated wire
3. Make a note of the part number of the appropriate pre-terminated lead
4. 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 Jaguar Land Rover (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:

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

Glue Lined Heat Shrink Sleeving 

There are 2 sizes of glue lined heat shrink sleeving available. Each heat shrink sleeve contains a sealant glue. These must be used when connecting wiring harness(s) or electrical connector terminal(s) at all times. The smaller diameter glue lined heat shrink sleeve is to be used with the red and blue splice connectors. The larger diameter glue lined heat shrink sleeve is to be used with the yellow splice connectors.

Wiring Harness Cable Identification Sleeves 

A selection of colored sleeves are available for maintaining the wiring harness cable identification on the pre-terminated lead.

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:

1. Black
2. Brown
3. Red
4. Orange
5. Yellow
6. Green
7. Blue
8. Violet
9. Gray
10. 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:

1. Put the green wiring harness cable identification sleeve on the pre-terminated lead first
2. Put the black wiring harness cable identification sleeve on the pre-terminated lead second
3. Slide both sleeves along the wiring harness cable to the electrical connector terminal.

Wiring Harness Repair Parts