1998 JAGUAR X308 length

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 harn ess 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 millimet res, of insulation to be strippe d. The amount of insulation to be stripped is shown in the
Relationship Table.
The illustration shows the insulation stri pper 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 Grippe d in Stripper Blades

Crimping Pliers
Crimping Pliers

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:
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 th e quick identification of electrical connectors and faulty pin
terminal(s).
Reference can also be made to the vehicle Electrical Guides, he ld 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
Electrical Connector Terminal Extraction
Tip G418-1241
Tip H418-1251
Tip I418-1261
Tip J418-1271
Tip K418-1281
Sleeve Identification Pa ck – for Red insulation418-112500
Sleeve Identification Pack – for Blue insulation 418-113500
Sleeve Identification Pack – for Yellow insulation 418-114500
Instruction Manual JTP 5931
Crimping Pliers YRW5000101
Wire Stripping Tool 418-1171
CABLE RANGE SPLICE STRIP LENGTH
0.35 mm² to 1.50 mm²RED6.00 to 7.00 mm
1.00 mm² to 2.50 mm²BLUE6.00 to 7.00 mm
4.00 mm² to 6.00 mm²YELLOW9.00 to 9.50 mm

Repair Procedure
• CAUTIONS: Do not use crimping pliers, insulation strippers, butt splice connectors, heat sh rink sleeves or pre-terminated wiring
harness(s) that are not supplied with the Jagu ar wiring harness repair kit. Each part has been designed to be used only with
the other parts in this wiri ng 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 elec trical connector using the extractor tool and correct tip. Make sure that any
anti-backout device is released befo re trying to remove the terminal.
CAUTION: : A number of electrical connector terminals ar e gold plated or gold flashed. When defective, they
must be installed with a gold pre-terminated wiring harnes s(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 failur e of the electrical contact.
• NOTE: Never use a harness lead with a smalle r diameter than the original harness lead.
Select the correct size and ty pe 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
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 connec tor is securely held in the aperture. This
will give support to the butt conn ector while the pre-terminated wiring harness is inserted into it.
• NOTE: See illustration: Spice Correctly Located
Insert the pre-terminated wiring harnes s 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 fre ed 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 harnes s(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 spli ce window over the guide bar. Make sure that the cable
harness wire is agains t 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 sp lice to make sure that a secure joint has been made.
AMP 6.3 flatDD
Econoseal III 250 seriesBF

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 un til the fuel spill has fully evaporated.
• CAUTIONS:
When using a heat source make sure that it is localised and caus es 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 wi ring harness insulation becomes damaged.
Using a suitable heat source, shrink the sleeve over the butt splice.
If further pre-terminated wiri ng harness(s) are to be installed to the sa me 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 ha rness 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 cove r and secure with adhesive electrical tape. Do not cove r the wiring harness right to the electrical connector as the terminals must have a little movement and no t 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
Spice Correctly Located

Exterior Trim and Ornamentation - Door Moulding
Removal and Installation
Removal
Installation

1.
Apply suitable protecti ve tape to immediately adjacent areas of
paintwork.
2. Using a hand-held heat gun, appply heat uniformly along
moulding length.
3. Applying local heat at one end and using a suitable thin lever
to avoid damaging paintwork, progressively ease moulding
away from door panel.
4. Discard moulding and remove protective tape.
5. Remove any residual adhesive and thoroughly clean area using
white spirit.
1. NOTE: Optimum adhesion is achi eved by warming body panel
and moulding to 65deg C.
Using white spirit ensure that mounting area is clean, dry and
de-greased.
2. Remove protective backing tape from moulding.
3. NOTE: Do not allow moulding to contact the body panel until it
is correctly aligned.
Heat moulding and moun ting area to 65degC.)
4. Aligning with adjacent mouldings or to match opposite side of
vehicle, press new moulding firmly onto body panel.
5. Apply hand pressure along moulding length to ensure
satisfactory adhesion.
6. Allow moulding and door panel to cool , then thoroughly clean
both using white spirit.
7. Apply a coat of suitab le polish to moulding and body panel.

Exterior Trim and Ornamentation - Front Fender Moulding
Removal and Installation
Removal
Installation

1.
Apply suitable protecti ve tape to immediately adjacent areas of
paintwork.
2. Using a hand-held heat gun, appply heat uniformly along
moulding length.
3. Applying local heat at one end and using a suitable thin lever
to avoid damaging paintwork, progressively ease moulding
away from fender.
4. Discard moulding and remove protective tape.
5. Remove any residual adhesive and thoroughly clean area using
white spirit.
1. NOTE: Optimum adhesion is achi eved by warming body panel
and moulding to 65deg C.
Using white spirit ensure that mounting area is clean, dry and
de-greased.
2. Remove protective backing tape from moulding.
3. NOTE: Do not allow moulding to contact the fender until it is
correctly aligned.
Heat moulding and mounting area to 65deg C.
4. Aligning with adjacent mouldings or to match opposite side of
vehicle, press new mouldi ng firmly onto fender.
5. Apply hand pressure along moulding length to ensure
satisfactory adhesion.
6. Allow moulding and fender to cool , then thoroughly clean both
using white spirit.
7. Apply a coat of suitable poli sh to moulding and fender.

8. Disconnect the radio antenn a electrical connector.

9. Apply suitable protec tive tape to the upper edge of the
headlining.
10. Prepare cheese wire and cutting handle.
Position cutting handle cent ral tube fully upwards in
handle.
Cut a suitable length of ch eese wire and pass one end
through handle tube and locating aperture.
Move cutting handle central tube downwards to secure
cheese wire.
11. Using a suitable long bladed tool, penetrate the rear window
adhesive approximately 150mm fro m the top of one rear pillar.

Cut a suitable length of cheese wire and pass one end
through handle tube and locating aperture.
Move cutting handle central tube downwards to secure
cheese wire.

12. Using a suitable long bladed tool, penetrate Betaseal
approximately 150mm from the top of one A pillar.

13. Pass free end of cheese wire through penetration and install
second cutting handle.

14. WARNING: When removing the windshield glass,
personal protection must be worn. Failure to follow this
instruction may result in personal injury.
• CAUTIONS:
Make sure the ch eese wire cannot contact the paintwork
while the the windshield adhesive is being cut. Failure to follow
this instruction may result in damage to the vehicle.
Make sure the cheese wire cannot contact the instrument
panel while the the windshield adhesive is being cut. Failure to
follow this instruction may result in damage to the vehicle.
Make sure the cheese wire passes the Vehicle Identification
Number (VIN) plate on the correct side. Failure to follow this
instruction may result in damage to the component.
When cutting, do not allow ch eese wire to contact edge of
windshield glass as this will crack the windshield glass.
• NOTE: Apply cutting lubricant to the cheese wire frequently
through out the cutting process.
With assistance and exercising care at the corners to avoid
damaging paintwork, cut around the windshield glass