Published: 11-May-2011

Wiring Harnesses - Wiring Harness

Description and Operation

Introduction

CAUTION: Do not use any other heat shrink sleeve other than the approved glue lined heat shrink sleeve mentioned
in the repair procedure.

The purpose of this document is to promote quick and efficient minor repair to harness connectors or cables using
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:

At the time of this first issue of the Harness Repair Guide, do not approve repairs to any of the following circuits:

Any media orientated system transport network harnesses.

Supplement restraint system (SRS) firing circuits (Air bags).
Link lead assembles, which are unique to safety critical circuits such as anti-lock brake system (ABS) and
thermocouple circuits. An example of this is the ABS wheel speed sensors with moulded connectors.
4. Screened cables, leads and wiring harness(s).

If any harness(s) with defective electrical connector terminals or wires from the above circuits are a concern,
new components must be installed.

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Repair Kit

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 to 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.

The wiring harness repair kit has been produced which comprises:

Pre-terminated wiring harness(s) of different sizes and types

Three sizes of butt splice connectors
A selection of colored cable identification sleeves
Two sizes of glue lined heat shrink sleeves
Crimping pliers
A wire cutter and insulation stripper
An electrical connector terminal extraction handle and tips

A suitable heat source, for shrinking heat shrink sleeves will be required.

The pre-insulated diamond grip range of electrical connector terminals and in-line, butt splice connectors contained within
the wiring harness repair kit are the only acceptable product for the repairs of wiring harnesses. The butt connectors not
only grip the wire but also the insulation, making a very secure joint.

If an electrical connector terminal is not included in the wiring harness repair kit then approval for the repair is NOT given
and in these circumstances a new wiring harness must be installed.

Pre-Terminated Wiring Harness(s) and Butt Splice Connectors

All pre-terminated wiring harness(s) and butt splice connectors in the wiring harness repair 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 wiring harness repair kit is identified with the corresponding part number. Make sure that pre-
terminated wiring harness(s) 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 wiring harness(s) are supplied with the insulation in one of three colors, red, blue or yellow. The colors
do not apply to any particular circuit but to the harness 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 pre-terminated
wiring harness insulation color.

Pre-Terminated Wiring Harness(s)

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The illustration shows:

The pre-terminated wiring harness(s) which are included in the wiring harness repair kit
The part number of the pre-terminated wiring harness
The letter showing the extractor tip which must be used to remove this type of electrical connector terminal
Those electrical connector terminals which are gold

Some of the pre-terminated wiring harness(s) have seals installed to the insulation for sealed connector applications. It is
essential for prevention of moisture ingress that a sealed pre-terminated wiring harness must be used where a sealed
terminal was removed.

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 to 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.

Two sizes of heat shrink sleeving are supplied in the wiring harness repair kit. 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 heat shrink sleeve is to be used with the red and blue butt splice connectors and the larger diameter sleeve with
the yellow butt splice connectors.

For ease and speed, some of the pre-terminated wiring harness(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 Relationship Table for the correct
length of insulation to be stripped.

The Pre-Terminated Wiring Harness(s) illustration shows the electrical connector terminal type, the part number of the
pre-terminated wiring harness and the letter of the extractor tip which must be used to extract the electrical connector
terminal from the connector housing. Additionally, those electrical connector terminal(s) which are gold are identified, all
others are therefore, tinned and not gold.

Wiring Harness Cable Identification Sleeves

A selection of colored sleeves are contained in the wiring harness repair kit for maintaining the wiring harness cable
identification on the pre-terminated wiring harness. Place the correct colored sleeve(s) over the pre-terminated wiring
harness insulation as near to the electrical connector as possible with the main wiring harness cable color nearest to the
electrical connector.

For example, if the original wiring harness cable color is pink with a black trace put the pink wiring harness cable
identification sleeve on the pre-terminated wiring harness first followed by a black sleeve, and slide both along the wiring
harness cable to the electrical connector terminal.

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Extraction Handle and Tips

The extraction handle, in conjunction with the correct tip, is used to remove a terminal from an electrical connector. Each
tip contained in the wiring harness repair kit is marked with an identification letter, A to K inclusive. Each tip has been
specially designed to extract a particular type of electrical connector terminal. The use of any other tool is not
recommended and is liable to cause damage to the electrical connector. The tip is fastened to the handle by a screw which
holds the tip firmly yet allows it to be easily replaced.

Extraction Handle and Tips

Insulation Stripper

The moving jaw has an adjuster wheel which has a series of holes in it. Turning the wheel and placing the cable in the
matching size hole will automatically adjust the jaw to the correct pressure. Note that some wiring harness(s) may have a
harder insulation and slight adjustment of the wheel may be needed to make a clean strip but exercise care not to
damage the wire.

Insulation Stripper

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By pressing the outer edges of the wiring harness cable length stop together the adjuster can be slid up or down the jaw.
This decreases or increases the length by which the wiring harness cable insulation will be stripped from the pre-
terminated wiring harness or wiring harness wire. The adjuster has a position indicator to align with a graduated scale and
this sets the correct length in millimetres, of insulation to be stripped. The amount of insulation to be stripped is shown in
the Relationship Table.

The illustration shows the insulation stripper tool and a wiring harness correctly gripped in the jaws. A wire cutter is
provided on the outer side of the fixed jaw.

Cable Correctly Gripped in Stripper Blades

Crimping Pliers

Crimping Pliers
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The crimping pliers have a moving jaw and a stationary jaw, with three different sized crimping enclosures. Each of the
enclosures is identified by a red, blue or yellow coloured dot which corresponds to the three colours of the pre-terminated
wiring harness(s) and butt splice connector colors.

List of Parts

Description Part Number Quantity

Wiring Harness Repair Kit 418-S065 1
Pre-Terminated Wiring Harness(s) 418-066 to 418-103 10 each
inclusive
Glue Lined Heat Shrink Pack – small diameter 418-104 25 per
pack
Glue Lined Heat Shrink Pack – larger diameter 418-105 10 per
pack
Case Assembly Comprising – carry case, lid, inner lid, base, insert, trays foam 418-106 1
spacers
Butt Splice Connector – Red 418-107 50 per
pack
Butt Splice Connector – Blue 418-108 50 per
pack
Butt Splice Connector – Yellow 418-109 20 per
pack
Extraction Tool Handle 418-110 1
Extraction Tip Pack consists of 2 spare screws plus 418-S111 1
Tip A 418-118 1
Tip B 418-119 1
Tip C 418-120 1
Tip D 418-121 1
Tip E 418-122 1
Tip F 418-123 1
Tip G 418-124 1
Tip H 418-125 1
Tip I 418-126 1
Tip J 418-127 1
Tip K 418-128 1
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
Instruction Manual JTP 593 1
Crimping Pliers YRW500010 1
Wire Stripping Tool 418-117 1
Items can be ordered from:

SPX United Kingdom Limited

Ironstone Way

Brixworth

Northants

NN6 9UD

United Kingdom

Telephone: +44 (0) 1327 704461

Fax: +44 (0) 1327 706632

Repair Methods

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

It is necessary to identify:

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The conductor (wire) size of the affected wiring harness
The electrical connector range from which the damaged wiring harness is to be removed
The 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 vehicle Electrical Guides, held by Dealers, to identify wiring harness(s) and electrical
connector(s).

By using the Relationship Table, the wiring harness conductor (wire) size can be related to a suitable pre-terminated
wiring harness by the color of the insulation. Also, the correct length of insulation to be stripped from the wiring harness
lead is identified.

Relationship Table

CABLE RANGE SPLICE STRIP LENGTH

0.35 mm² to 1.50 mm² RED 6.00 to 7.00 mm
1.00 mm² to 2.50 mm² BLUE 6.00 to 7.00 mm
4.00 mm² to 6.00 mm² YELLOW 9.00 to 9.50 mm
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 and these have been included in the kit. Most can be released by
carefully using a suitable small screwdriver.

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 each tip used on different types of electrical connector(s). There are a large number of
different types of electrical connector used on vehicles therefore only one example using each tip is shown. Technicians
experience and judgement will dictate which type of tip should be used for those electrical connector(s) which are not
shown. Care should be exercised to avoid further damage when removing the terminals from the electrical connector.

NOTE: Examples of the extraction tips and anti-backout tips.

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NOTE: The chart shows the electrical connector types, terminal pins/sockets, extractor tip and anti-backout tip.

Electrical connector terminal type Pin or socket Extractor tip Anti-backout tip
Mulitlock 040 series D A
Mulitlock 040 series B A

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Mulitlock 070 series B B
Mulitlock 040 series D B
Econoseal III 070 series D B
Econoseal III 070 series B B
Econoseal III 070 series B B
Econoseal III J2 D B
Econoseal III 250 series B F
Econoseal III 250 series D B
Econoseal III 250 series B F
Econoseal III 250 series D B
Micro-timer II 1.5mm D C
Micro-timer II 1.5mm B C
Std power timer 4.8 flat D G
Std power timer 5.8 flat B D
Std power timer 5.8 flat B D
Std power timer 2.8 flat D D
Std power timer 4.8 flat D G
Std power timer 5.8 flat B D
Ford 2.8 flat D E H
Mulitlock 070 series D B
Mulitlock 070 series B B
Junior power timer 2.8 flat D D
Sumitomo TS90 connector B B H
Modu IV gold plated D B
Mulitlock 040 series gold plated D A
Micro qualock D I
EECV D B
EECV D B
Kostal dia 1.50 series D J
AMP 6.3 flat D B
Junior power timer 2.8 flat D D
2.8 series D B I
Sumitomo TS90 connector D B H
Ducon 0.60 gold plated D K
AMP 6.3 flat D D
Econoseal III 250 series B F

Repair Procedure

CAUTIONS:
 Do not use crimping pliers, insulation strippers, butt splice connectors, heat shrink sleeves or pre-terminated wiring
harness(s) that are not supplied with the Jaguar wiring harness repair kit. Each part has been designed to be used only
with the other parts in this wiring harness repair kit.

Where the repair procedure indicates that a glue lined heat shrink sleeve should be applied, apply sufficient heat to
the glue lined heat shrink to 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.

It is not correct to make more than five repair joints on the wiring harness to any electrical connector and if more damage
is found at the same electrical connector then a new wiring harness must be installed.

Remove the faulty terminal from the electrical connector using the extractor tool and correct tip. Make sure that
any anti-backout device is released before trying to remove the terminal.

CAUTION: : A number of electrical connector terminals are gold plated or gold flashed. When defective, they
must be installed with a gold pre-terminated wiring harness(s) from the wiring harness repair kit. It is not always
easy to identify the female as gold but the male pins are visually easier, therefore always check 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 harness and butt splice connector from the wiring harness
repair kit.
Using the wire cutter on the stripping tool, cut the pre-terminated wiring harness and the harness cable to the
required length.
NOTE: See illustration: Stripping Insulation

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From the Relationship Table, find the correct length of insulation to be stripped from the pre-terminated wiring
harness and set the adjustable cable length stop to the correct length. Place the pre-terminated wiring harness in
the wire stripper and remove the insulation.
Put the cable identification sleeve(s) on to the wiring harness with the main cable colour nearest to the terminal.
During this next step do not overtighten. Place the selected butt splice connector in the crimping tool, matching the
aperture and the butt connector colours. Make sure that the window indentation in the butt connector is resting
over the guide bar on the lower jaw. Partially close the grip until the butt connector is securely held in the
aperture. This will give support to the butt connector while the pre-terminated wiring harness is inserted into it.
NOTE: See illustration: Spice Correctly Located

Insert the pre-terminated wiring harness into the butt connector and make sure that the wire is against the wire
stop. Close the grip firmly, crimping the lead to the butt connector. When the handles have been completely closed
the butt 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 butt connector and it cannot be removed from the tool until the crimp is fully
made by closing the handles completely.
Make sure that the harness cable has been squarely cut and the correct length of insulation removed. If more than
one splice is needed the butt 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.
It is preferable to cover the butt splice joint with heat shrink sleeve. This is desirable not essential, except where
the electrical connector is a sealed electrical connector. Use the smaller diameter sleeve for red and blue pre-
terminated wiring harness(s) and the large diameter sleeve for the yellow pre-terminated wiring harness(s). It is
advisable to place the heat shrink over the completed joint but in some instances the sleeve will not pass over the
terminal. Check, and if required, place the correct size sleeve onto the harness cable or pre-terminated wiring
harness before crimping the butt splice to the wiring harness.
Place the harness cable into the butt splice with the splice window over the guide bar. Make sure that the cable
harness wire is against the stop in the butt splice, crimp the butt splice connector to the wiring harness.
Gently pull the harness cables each side of the butt splice to make sure that a secure joint has been made.

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.

CAUTIONS:

When using a heat source make sure that it is localised 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 to 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 butt splice.
If further pre-terminated wiring harness(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 one area.
When all of the splices have been made, fit the terminal(s) to the electrical connector, taking care that the
 terminals are correctly orientated.
Install the wiring harness cover and secure with adhesive electrical tape. Do not cover the wiring harness right to
the electrical connector as 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

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Spice Correctly Located
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 Published: 11-May-2011
Wiring Harnesses - Wiring Harness Repair
General Procedures

1. For additional information, refer to: Wiring Harness (418-02,

Description and Operation).

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 Published: 29-Nov-2011
Wiring Harnesses - Engine Wiring Harness
Removal and Installation

Removal
CAUTIONS:

Make sure that the wiring harness is not twisted or damaged on removal. Failure to follow this instruction may result
in damage to the vehicle.

Take extra care not to damage the wiring harness clips.

NOTE: Note the position of the wiring harnesses to aid installation.

1. For additional information, refer to: Intake Manifold (303-01 Engine

- ID4 2.2L Diesel, Removal and Installation).

2. WARNING: Do not work on or under a vehicle supported only

by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

3.

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4. Torque: 5Nm
7.
6.
5.

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8.

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9. Torque: 10Nm

10.
13.
12.
11.

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15.
14.

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16. Torque: 8Nm

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17.

18. Positive cable nut torque: 12Nm, Solenoid cable nut

torque: 8Nm
19.

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20. Torque: 24Nm

21.
24.
23.
22.

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Installation
1. To install, reverse the removal procedure.

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