2006 LAND ROVER FRELANDER 2 Repair Manual

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LAND ROVER FRELANDER 2 2006 Repair Manual The cri mping pli ers have a movi ng jaw and a s t at ionary jaw, wi th t hree di fferent s ized cri mping enclos ures. Each of t heencl osures is i dent ified by a red, blue or yell ow coloured do

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LAND ROVER FRELANDER 2 2006 Repair Manual Ironst one W ay
Bri xwort h
Nort hant s
NN6 9UD
Unit ed Kingdom
Telephone: +44 (0) 1327 704461
Fax: +44 (0) 1327 706632
Repair Methods
CAUTION: Several different types and sizes of terminal may be fou

Ironst one W ay
Bri xwort h
Nort hant s
NN6 9UD
Unit ed 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 neces s ary to i dent ify:
The conductor (wire) si ze of the affected wiri ng harnes sThe electrical connect or range from which t he damaged wiri ng harnes s is to be removedThe t ermi nal t ype
Us e of the approved di agnos ti c tool wi ll greatl y as si s t in t he quick i dent ificati on of el ect ri cal connectors and faul ty pi nt ermi nal (s ).
Reference can als o be made to the vehicle Elect rical Gui des , held by Deal ers , to identi fy wi ri ng harness (s ) and el ect ri calconnector(s ).
By us ing t he Relat ionshi p Table, the wiring harnes s conductor (wire) si ze can be relat ed t o a s uit able pre-t ermi nat edwiring harnes s by t he color of the ins ul ati on. Al so, t he correct lengt h of ins ulati on t o be s tripped from the wiri ng harnes slead i s ident ifi ed.
Relationship Table
CABLE RANGESPLICEST RIP LENGT H
0.35 mm² t o 1.50 mm²RED6.00 t o 7.00 mm1.00 mm² t o 2.50 mm²BLUE6.00 t o 7.00 mm
4.00 mm² t o 6.00 mm²Y ELLO W9.00 t o 9.50 mm
Electrical Connector Terminal Extraction
It must be not ed t hat s ome el ect ri cal connect or(s ) have anti -backout devices which prevent the t erminals from beingremoved from the el ect ri cal connect or. Some examples of t hes e are s hown in foll owing i llus t rat ions. The ant i-backoutdevi ce mus t be rel eas ed before att empt ing t o remove the t ermi nal from t he electrical connect or. Some ant i-backoutdevi ces require a s peci al t ip to releas e t he devi ce and thes e have been included in the kit . Mos t can be rel eas ed bycareful ly us ing a sui table small s crewdriver.
Vari ous types of el ect ri cal connect or have s eals i ns t alled internal ly or ext ernally to prevent moi st ure ingres s . Thes enormal ly do not have t o be removed but make s ure that t hey are i ns t alled when the elect ri cal connectors are connect ed.
The il lus trati ons show exampl es of each t ip us ed on di fferent types of electrical connect or(s). There are a l arge number ofdifferent t ypes of el ect ri cal connector us ed on vehi cles t herefore onl y one example us ing each t ip is s hown. Techniciansexperience and judgement wil l di ct ate which t ype of t ip should be used for t hos e el ect ri cal connector(s ) which are nots hown. Care s houl d be exercis ed t o avoi d further damage when removi ng the terminals from t he electrical connect or.
• NOTE: Examples of the extraction tips and anti-backout tips.

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LAND ROVER FRELANDER 2 2006 Repair Manual

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LAND ROVER FRELANDER 2 2006 Repair Manual • NOTE: The chart s hows the el ect ri cal connector t ypes , t ermi nal pins /socket s , ext ra
ctor t ip and ant i-backout ti p.
Electrical connector terminal type Pin or socketExtractor tip An

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LAND ROVER FRELANDER 2 2006 Repair Manual Electrical connector terminal typePin or socketExtractor tipAnti-backout tip
Muli tl ock 040 seriesDB
Econos eal III 070 seriesDBEconos eal III 070 seriesBB
Econos eal III 070 seriesBB
Econos eal III

Electrical connector terminal typePin or socketExtractor tipAnti-backout tip
Muli tl ock 040 seriesDB
Econos eal III 070 seriesDBEconos eal III 070 seriesBB
Econos eal III 070 seriesBB
Econos eal III J2DBEconos eal III 250 seriesBF
Econos eal III 250 seriesDB
Econos eal III 250 seriesBFEconos eal III 250 seriesDB
Mi cro-t imer II 1.5mmDC
Mi cro-t imer II 1.5mmBCSt d power t imer 4.8 flatDG
St d power t imer 5.8 flatBD
St d power t imer 5.8 flatBDSt d power t imer 2.8 flatDD
St d power t imer 4.8 flatDG
St d power t imer 5.8 flatBDFord 2.8 flatDEH
Muli tl ock 070 seriesDB
Muli tl ock 070 seriesBBJuni or power t imer 2.8 fl atDD
Sumit omo TS90 connect orBBH
Modu IV gold pl atedDBMuli tl ock 040 series gold pl atedDA
Mi cro qualockDI
EECVDBEECVDB
Kos tal dia 1.50 s eri esDJ
AMP 6.3 flatDBJuni or power t imer 2.8 fl atDD
2.8 s eriesDBI
Sumit omo TS90 connect orDBHDucon 0.60 gold platedDK
AMP 6.3 flatDD
Econos eal III 250 seriesBF
Repair Procedure
• CAUTIO NS:
Do not us e cri mping pl iers , i ns ulat ion s t ri ppers, but t s pl ice connectors , heat s hrink sl eeves or pre-t ermi nat ed wiringharnes s(s ) that are not s uppli ed wit h t he Jaguar wiring harnes s repai r ki t. Each part has been desi gned to be used onl ywit h t he ot her part s i n t hi s wi ring harnes s repai r kit .
W here t he repair procedure i ndicat es t hat a glue l ined heat shrink s leeve s houl d be appli ed, apply s uffici ent heat tot he glue l ined heat shrink t o mel t the gl ue in order to provi de a wat er ti ght s eal. Do not over heat t he glue lined heats hrink sl eeve s o that the wiring harnes s ins ulat ion becomes damaged.
It is not correct t o make more t han fi ve repair joi nts on the wiri ng harnes s to any elect rical connect or and i f more damageis found at the same electrical connect or then a new wiring harnes s mus t be i ns t alled.
Remove the fault y t ermi nal from the el ect ri cal connector us ing t he extract or tool and correct t ip. Make s ure t hat anyanti -backout devi ce is releas ed before trying t o remove the t ermi nal.
CAUTION: : A number of electrical connect or terminals are gold plated or gol d fl ashed. W hen defect ive, theymus t be ins t al led wit h a gold pre-t erminated wi ri ng harnes s(s ) from t he wi ring harnes s repai r kit . It i s not alwayseasy to ident ify t he femal e as gold but t he mal e pins are vis ually eas ier, therefore al ways check both male andfemal e t ermi nal s t o identi fy thos e which are gold. Under no ci rcums tances are gold and ti n t ermi nal s t o be mi xedas t hi s wi ll lead t o earl y fai lure of the el ect ri cal contact.
• NOTE: Never us e a harness lead wit h a smaller diamet er than t he ori ginal harness lead.
Select the correct s i ze and type of pre-terminat ed wiring harnes s and butt spl ice connector from the wi ri ng harnes srepair ki t.Us ing t he wi re cutt er on t he s tripping t ool, cut the pre-t ermi nat ed wi ring harnes s and t he harnes s cabl e t o t herequired lengt h.• NOTE: See il lus trati on: Stripping Insulation
From the Rel ati ons hip Table, find t he correct l engt h of ins ulat ion t o be s t ripped from the pre-t erminated wi ri ngharnes s and s et t he adjus t abl e cabl e lengt h s top t o t he correct l engt h. Pl ace the pre-t ermi nat ed wi ring harnes s i nt he wire s tripper and remove t he ins ulat ion.Put the cable ident ificati on s leeve(s ) on t o t he wiring harnes s wi th the mai n cabl e colour nearest t o t he t ermi nal .Duri ng thi s next s t ep do not overti ght en. Place the sel ect ed but t s pli ce connect or in t he cri mping t ool, mat chi ng theapert ure and t he butt connect or colours . Make s ure that t he window i ndent at ion in t he butt connect or is rest ingover t he guide bar on t he lower jaw. Parti ally cl ose the grip unt il t he but t connector i s s ecurel y held i n t he aperture.This wi ll give s upport t o t he but t connector whi le t he pre-terminat ed wiring harnes s i s ins ert ed int o i t.• NOTE: See il lus trati on: Spice Correctly Located

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LAND ROVER FRELANDER 2 2006 Repair Manual Ins ert the pre-t ermi nat ed wi ring harnes s i nto the but t connect or and make s ure t hat the wire is agains t t he wires top. Clos e t he gri p firmly, crimping t he lead t o t he butt conn

Ins ert the pre-t ermi nat ed wi ring harnes s i nto the but t connect or and make s ure t hat the wire is agains t t he wires top. Clos e t he gri p firmly, crimping t he lead t o t he butt connect or. W hen t he handles have been complet ely clos edt he but t connector wi ll be freed from the t ool as the handles are rel eas ed. If t he handl es have not been complet elyclos ed then t he jaws wil l hol d t he but t connector and i t cannot be removed from the tool unt il t he cri mp i s ful lymade by clos ing the handles complet el y.Make s ure t hat the harnes s cable has been s quarely cut and t he correct length of i nsul ati on removed. If more t hanone s plice i s needed the but t connect ors must be not be crimped t o t he wiring harness at t he s ame dis t ance fromt he connect or. The s pli ces must be st aggered to prevent a bul k of s plices i n the same area of t he wiring harnes s .It is preferable to cover the but t s pl ice joint wit h heat s hrink s l eeve. This i s desi rable not es s ent ial , except wheret he elect rical connect or i s a s ealed el ect ri cal connector. Use the smal ler diamet er sl eeve for red and bl uepre-terminat ed wiring harnes s (s ) and t he large diameter s leeve for the yell ow pre-terminat ed wiring harnes s (s ). Itis advis able to pl ace the heat s hrink over t he compl eted joint but in s ome ins tances the s l eeve wi ll not pass overt he terminal. Check, and i f required, pl ace t he correct s ize sl eeve ont o t he harness cable or pre-t ermi nated wi ri ngharnes s before crimpi ng the but t s plice t o t he wi ring harnes s .Place t he harness cable int o the but t s plice wi th the spl ice window over t he gui de bar. Make s ure that the cableharnes s wire i s agai nst t he s top in t he butt s pli ce, crimp the but t spl ice connector t o t he wiring harnes s .Gentl y pull the harnes s cables each s ide of t he butt s pli ce to make sure t hat a s ecure joint has been made.
W ARNING: Do not use a naked flame in areas where fuel or oi l have been s pil t. Clean t he area of res idual oi land fuel and wait unt il t he fuel s pi ll has ful ly evaporat ed.
• CAUTIO NS:
W hen us i ng a heat source make s ure t hat it is local is ed and causes no damage t o s urroundi ng mat erial s.
W here t he repair procedure i ndicat es t hat a glue l ined heat shrink s leeve s houl d be appli ed, apply s uffici entheat to t he glue lined heat s hri nk to melt t he glue i n order t o provide a water t ight s eal . Do not over heat t he glueli ned heat s hri nk s leeve s o t hat t he wi ring harnes s i nsul ati on becomes damaged.
Us ing a sui table heat s ource, shrink t he s leeve over t he butt s pli ce.If furt her pre-t erminated wi ri ng harnes s(s ) are t o be i nst all ed to the same elect rical connect or, make s ure that thelead i s cut at a different l engt h t o t he previous joi nt. This makes s ure that t he s pl ices wi ll, where poss i bl e, bes taggered on t he wi ri ng harness and prevent a bul k of s pl ices in one area.W hen al l of t he s pli ces have been made, fi t the t erminal(s) t o t he electrical connect or, t aking care t hat thet ermi nal s are correctl y ori ent ated.Ins t all the wiring harnes s cover and s ecure wi th adhes ive electrical tape. Do not cover t he wiring harnes s right tot he elect rical connect or as the t ermi nals mus t have a l it tl e movement and not be firml y bound to t he elect ricalconnector or wiring harnes s . Make s ure t hat the cable i dent ificati on s leeve(s ) are showing at t he wi ri ng harnesselectrical connect or.
Stripping Ins ulati on
Spice Correct ly Located

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