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 faulty 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 defective, 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.
    CAUTION:

    1. When using a heat source make sure that it is localized and causes no damage to surrounding materials.
    2. 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.

Stripping Insulation 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

Splice Correctly Located 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC