Pre-terminated wire harnesses and butt connectors (Freelander 2)

All pre-terminated wire harnesses and butt connectors in the wire harness repair kit are stored in bags that can be resealed after use. Each bag is labeled with the part number of the parts stored in the bag. Each storage compartment in the wire harness repair kit is labeled with the corresponding part number. Make sure that the pre-terminated wire harnesses and connectors are not mixed: it is recommended to open one bag at a time and reseal the bag before opening the next one. Also, place the bag in the storage compartment of the boot with the corresponding part number.

Pre-terminated wire harnesses come with one of three colors of insulation - red, blue, or yellow. The colors do not refer to a specific circuit, but rather indicate the cross-section of the wire in the harness. See the comparison table in the Repair Method section.

Butt connectors also come in red, blue and yellow which should match the color of the insulation on the termination wire harness.

Wiring harness with termination

The figure shows:

• Wire harnesses with termination included in the wire harness repair kit
• Wiring harness part number with termination
• Letter indicating the extractor tip that should be used to remove a given type of contact from an electrical connector
• Gold plated contacts of electrical connector

Some pre-terminated wire harnesses have seals that are installed on the insulation for use where a sealed connector is required. If a sealed contact has been removed, a sealed pre-terminated wire harness should be used to prevent moisture ingress.

CAUTION: If the repair procedure specifies the use of adhesive heat shrink sleeve, heat the sleeve to the melting point of the adhesive to ensure a tight seal. Do not overheat the adhesive heat shrink sleeve to avoid damaging the wire harness insulation.

The harness repair kit contains two sizes of heat shrink sleeves. Each heat shrink sleeve contains a sealing adhesive. These sleeves must be used when connecting harnesses or electrical connector contacts. The smaller diameter heat shrink sleeve is used with red and blue butt connectors, and the larger size is used with yellow butt connectors.

To simplify and speed up the procedure, some pre-terminated wire harnesses may already have partially stripped insulation on the splice side. If the repair requires stripping insulation on the cable, see the comparison table for the length of insulation to be removed.

The "Terminated Wire Harness" illustration shows the type of electrical connector contact, the part number of the terminated wire harness, and the letter of the extractor tip that should be used to extract the contact from the connector housing. In addition, the gold plated contacts of the electrical connector are marked, all others are not gold plated but tin plated.

Identification sleeves for cables and wire harnesses

The wire harness repair kit contains several colored sleeves to help maintain identification of the harness cables in the pre-terminated wire harness. Slide the correct color sleeve over the pre-terminated wire harness insulation as close to the electrical connector as possible so that the primary color of the harness cable is closest to the electrical connector.

For example, if the original wire harness cable color is pink with a black line, slide the pink wire harness cable identification sleeve over the termination harness, followed by the black sleeve, and slide both sleeves along the harness cable to the electrical connector terminal.