Do not use crimping pliers, wire strippers, butt connectors, heat shrink sleeves, or terminated wire harnesses not included in the Jaguar Harness Repair Kit. Each part is for use with other parts in the harness repair kit only.
If the repair procedure calls for the use of an adhesive heat shrink sleeve, heat the sleeve to the melting point of the adhesive to ensure the seal is tight. Do not overheat the adhesive heat shrink sleeve to avoid damage to the wire harness insulation.
Do not make more than five repair joints in the wiring harness for any electrical connector; if more than five faults are found in one electrical connector, a new wiring harness must be installed.
Using an extractor and a correct tip, remove the bad pin from the electrical connector. Make sure the retainer is released before removing the contact.
CAUTION:: Some contacts in the electrical connectors are gold-plated or gold-plated. In the event of failure, they should be replaced with a gold-plated wire harness terminated from the wire harness repair kit. It is difficult to determine the presence of gold plating in the socket, but the pins of the plug are easier to visually determine, so be sure to check the contacts of both the socket and the plug for the presence of gold plating. In no case should you mix gold-plated and tin-plated contacts, this will lead to premature failure of the electrical connector.
NOTE: Do not use wire that is smaller than the original diameter in the harness.
Select the correct size and type of Terminated Wire Harness and Butt Connector from the Wire Harness Repair Kit.
Using wire cutters on a wire stripping tool, cut the terminated wire harness and harness cable to the required length.
NOTE: See illustration: Insulation Stripping
In the comparison table, find the correct length of insulation cut on the terminated wire harness, and set the desired length on the adjustable stop. Clamp the terminated wire harness in a wire stripper and remove the insulation.
Slide the cable identification sleeves onto the wire harness so that the base color of the cable is at the terminal.
In the next step, do not overtighten. Place the selected butt connector in the crimping tool, ensuring that the holes and colors of the butt connector match. Ensure that the recess on the butt connector is positioned over the bottom clamp guide. Partially squeeze the handles so that the butt connector is securely locked in the hole. This will ensure that the butt connector does not move when the terminated wire harness is inserted into it.
NOTE: See illustration: Correct splice location
Insert the terminated wire harness into the butt connector and make sure the wire is against the stopper. Squeeze the handles firmly, crimping the wire into the butt connector. When the handles are fully closed, the butt connector will release from the tool when they are released. If the handles are not fully closed, the clamps will hold the butt connector and it will not be possible to remove it from the tool until the wire is completely crimped (full closing of handles).
Make sure the harness cable is properly cut and the correct section of insulation is removed. If multiple splice points are required, butt connectors should not be crimped onto the wire harness at the same distance from the electrical connector. Splice points must be spaced apart to prevent multiple splice points from being located in the same area of the wire harness.
It is recommended to cover the splicing area with a heat shrink sleeve. This is not a requirement except for electrical connectors with seals. The small diameter sleeve is used for the red and blue terminated wire harnesses, and the large diameter sleeve is used for the yellow ones. It is recommended to place a heat shrink sleeve over the finished joint, however in some cases the sleeve does not pass over the contact. Check and, if necessary, install the correct size sleeve on the harness cable or terminated harness before crimping the splice to the harness.
Place the wire harness cable into the butt joint so that the hole is above the guide. Make sure the harness wire is pressed against the stop in the butt joint, then crimp the butt connector onto the harness.
Gently pull on the wire harness on either side of the splice to check if the splice is secure.
WARNING: Do not use open flames where fuel or oil has been spilled. Clean the area of oil and fuel residues and wait for the spilled fuel to evaporate.
When using a heat source, make sure it is localized and will not damage surrounding materials.
If the repair procedure calls for the use of an adhesive heat shrink sleeve, heat the sleeve to the melting point of the adhesive to ensure the seal is tight. Do not overheat the adhesive heat shrink sleeve to avoid damage to the wire harness insulation.
Using a suitable heat source, heat shrink the sleeve at the splice.
If additional terminated harnesses will be installed to the same electrical connector, make sure the wire is cut at a different distance from the previous splice. This will provide separation (if possible) splice points on the wiring harness and will prevent multiple splices in one place.
When splicing is complete, install the contacts into the electrical connector. Ensure the correct orientation of the contacts.
Install the wiring harness cover and secure with adhesive tape. Do not close the wiring harness all the way to the electrical connector, as the pins need to be slightly movable and not be firmly embedded in the connector or wiring harness. Make sure the identification sleeves are visible at the wiring harness electrical connector.
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