Approved Electrical Wiring Harness Repair Methods

CAUTION: Several different types and sizes of terminal may be found in a single electrical connector housing.

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 JLR approved diagnostic equipment will greatly assist in the quick identification of electrical connectors and damaged pin terminal(s).

Reference can also be made to the ERL and Interactive Electrical Wiring Diagrams (iEWD) available through Service Information, to identify wiring harness(s) and electrical connector(s).

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.

ELECTRICAL WIRING HARNESS REPAIR RELATIONSHIP DESCRIPTION

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 service information 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.

CAUTION: Inspect the electrical connector housing for evidence of damage. The damage may affect the security of a terminal inside the connector housing. The damage may affect the operation of the anti-backout device. The damage may affect the secure installation of the connector housing to the intended component/connector housing. Replace a damaged electrical connector housing.

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.

NOTE: Examples of the extraction tools and anti-backout devices.