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 approved diagnostic tool will greatly assist in the quick identification of electrical connectors and faulty pin terminal(s).

Reference can also be made to the appropriate Wiring Diagrams

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.

CABLE SIZE RANGE	SPLICE CONNECTOR	STRIP LENGTH
0.35 to 1.50 mm2 (0.00054 to 0.0023 inch2 )	RED	6.00 to 7.00 mm (0.23 to 0.27 inch)
1.00 to 2.50 mm2 (0.0016 to 0.0039 inch2 )	BLUE	6.00 to 7.00 mm (0.23 to 0.27 inch)
4.00 to 6.00 mm2 (0.0062 to 0.0093 inch2 )	YELLOW	9.00 to 9.50 mm (0.35 to 0.37 inch)

Electrical Connector Terminal Extraction 

It must be noted that some electrical connector(s) have anti-backout devices which prevent the terminals from being removed from the electrical connector. Some examples of these are shown in following illustrations. The anti-backout device must be released before attempting to remove the terminal from the electrical connector. Some anti-backout devices require a special tip to release the device. Please refer to the appropriate Wiring Diagrams for the correct tool(s) to use (where applicable).

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.

A 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

B 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

C 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

D - 1 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

D - 2 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

E 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

F 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

G 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

H 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

I 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

J 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

K 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

L 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

M 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

N 

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC