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 damaged 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 damaged, 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:

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

    4.4 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 the Electrical Wiring Harness Repair Relationship Table in the Section 4.1.

    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 the Electrical Wiring Harness Repair Relationship Table in the Repair Methods section. 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 ERL or Interactive Electrical Wiring Diagrams (iEWD) available through TOPIx.

    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 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:

16. Put the green wiring harness cable identification sleeve on the pre-terminated lead first
17. Put the black wiring harness cable identification sleeve on the pre-terminated lead second
18. 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

    4.5 WIRING HARNESSES

    CAUTION: Disconnect the battery before commencing the repair of any wiring harness.

    The repair is only appropriate where the damage is localised and is not over the full length of the wiring harness. If the damage is end to end then replacing the whole harness should be considered where appropriate. The damaged section of wiring harness must be removed by cutting either side of the damage at a point where the wiring harness retains its original condition. The number of twists in a twisted pair of wires is important to the functionality of the circuit and as such must be maintained. Note the number of twist over the repair length prior to commencing the repair. The same number of twists must reintroduced after completing the repair.

    If repairing multiple wires within a harness, stagger the connecting splices and twist the wire between the connecting splice locations. This will minimize the untwisted length and the effect of increasing the diameter of the harness. On no account must the untwisted length exceed 50 mm (2.0 inch) each side of the connecting splice. When each connecting splice repair is completed, cover the splice with a black glue lined heat shrink sleeve. Use an approved hot air applicator to shrink the sleeve until the glue is visible at both ends. Make sure that connecting splice repairs are not located in any dynamic movement area of a harness.

    When all wiring harness repairs are complete, the wiring harness must be wrapped in insulating tape and returned as close as possible to new vehicle condition. Make sure the wiring harness follows the original routing and all clips and connectors are secured.

    CAUTION: Under no circumstances should repair be attempted to the following:

    • Link lead assembles, which are unique to safety critical circuits such as ABS  and thermocouple circuits. An example of this is the ABS  wheel speed sensors with moulded connectors.
    • Throttle Control circuits.
    • Speed Control circuits.
    • Screened cables, leads and wiring harness(s).

    If any harness(s) with damaged electrical connector terminals or cables from the above circuits give cause for concern, new components must be installed.

    CAUTION:

    • Do not attempt to repair or reform a damaged electrical connector terminal. A damaged electrical connector terminal must be replaced using the correct pre-terminated lead.
    • A ground point connector with multiple wires to the connector must not be repaired as a complete connector. If a damaged wire is identified, the wire can be repaired individually using the correct pre-terminated lead.
    • Do not attempt the repair of damaged battery, hybrid and power cables.

      These types of cable generally have a cross sectional area larger than 6 mm² (0.009 inch² ) and must only be replaced. If the original cable is contained within the harness bundle the original cable must be left in the harness. Attach the replacement cable to the harness along the original harness route.

      The replacement cable must follow the original cable route to avoid the risk of introducing electrical interference issues. The original cable connections must be cut from the cable at both ends and discarded. The exposed cable ends must be free from sharp edges and strands of wire. The exposed cable must be over taped to prevent injury before being taped back to the main harness.

    If any harness(s) with damaged electrical connector terminals or cables from the above circuits give cause for concern, new components must be installed.

    4.5.1 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 the Electrical Wiring Harness Repair Relationship Table in the Repair Methods section.

    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 the Electrical Wiring Harness Repair Relationship Table in the Repair Methods section. 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 Electrical Reference Library (ERL) or Interactive Electrical Wiring Diagrams (iEWD) available through TOPIx.

    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 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:

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

Wiring Harness Repair Parts