WIRING HARNESS REPAIR INTRODUCTION The purpose of this document is to promote quick and efficient minor repair to harness connectors or cables using Jaguar Cars approved methods and the Wiring Harness Repair Kit. Repairs may only be made to cables and connectors which have been mechanically, not electrically, damaged. It also applies where the whole extent of the damage can be clearly identified and rectified. Care and neatness are essential requirements in making a perfect repair.
CAUTION:
Jaguar Cars Limited, at the time of this first issue of the Harness Repair Guide, do not approve repairs to any of the following circuits: 1. Any media orientated system transport (MOST) network harnesses. 2. Supplement restraint system (SRS) firing circuits (Air bags). 3. 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. 4. Screened cables & leads. Any harnesses with defective terminations or cables from the above circuits must be replaced.
REPAIR KIT A Jaguar Cars Wiring Harness Repair Kit has been produced which comprises: • pre-terminated leads of different sizes and types • three sizes of butt splice connectors • a selection of coloured cable identification sleeves • two sizes of heat shrink sleeve • crimping pliers • a wire cutter and insulation stripper • a termination extraction handle and tips A suitable heat source, for shrinking heat shrink sleeves will be required. The PIDG (Pre-Insulated Diamond Grip) range of terminations and in-line, butt splice connectors contained within the Repair Kit are the only acceptable product for the repairs of Jaguar Cars wiring harnesses. The butt connectors not only grip the wire but also the insulation, making a very secure joint. If a termination is not included in the kit then approval for the repair is NOT given and in these circumstances the harness must be replaced.
Pre-Terminated Leads and Butt Splice Connectors All pre-terminated leads and butt splice connectors in the kit are contained in bags which can be resealed after use. Each bag is marked with the part number of the items stored within the bag. Each storage compartment in the kit is identified with the corresponding part number. To ensure that pre-terminated leads and connectors are not mixed up it is advisable to only open one bag at a time and to reseal the bag securely before opening another bag. Also, replace the bag in its mating part number compartment within the case. The pre-terminated leads are supplied with the insulation in one of three colours, red, blue or yellow. The colours do not apply to any particular circuit but to the lead wire size. See the Relationship Table in the Repair Method section. Butt splice connectors are also supplied with red, blue or yellow coverings, which must be matched to the preterminated lead insulation colour. The illustration on the next page shows: the pre-terminated leads which are included in the kit the part number of the pre-terminated lead the letter showing the extractor tip which must be used to remove this type of termination those terminations which are gold Some of the pre-terminated leads have seals fitted to the insulation for sealed connector applications. It is essential for prevention of moisture ingress that a sealed pre-terminated lead must be used where a sealed termination was removed.
November 2005, issue 2
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