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.

NOTE: A suitable heat source, for shrinking the glue lined heat shrink sleeves will be required.

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

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 The correct length of insulation to be stripped will be detailed in the table.

Wire Chart and Service Repair Information

This information is part of the relevant Wiring Diagrams

NOTE: Access to information about the pre-terminated leads for vehicles supported by the iEWD is achieved by hovering the screen pointer over the relevant connector number and left-clicking.

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 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:

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

CAUTION:

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 and provide a water tight seal. Do not over heat the glue lined heat shrink sleeve so that the wiring harness insulation becomes damaged.
Do not use any heat shrink sleeve other than the approved glue lined heat shrink sleeve specified in the repair procedure.

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:

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:

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

Wiring Harness Repair Parts

NOTE: Repair components can be ordered through the JLR parts ordering system.

DESCRIPTION	PART NUMBER	QUANTITY
Glue Lined Heat Shrink Sleeve Pack - small diameter	418-104	25 per pack
Glue Lined Heat Shrink Sleeve Pack - larger diameter	418-105	10 per pack
Case Assembly Comprising - carry case, lid, inner lid, base, insert, trays foam spacers	418-106	1
Splice Connector - Red	418-107	50 per pack
Splice Connector - Blue	418-108	50 per pack
Splice Connector - Yellow	418-109	20 per pack
Sleeve Identification Pack - for Red insulation	418-112	500
Sleeve Identification Pack - for Blue insulation	418-113	500
Sleeve Identification Pack - for Yellow insulation	418-114	500