2010 JAGUAR XFR Workshop Manual

CD player wheel handbrake alternator engine oil capacity transmission fluid

Page 2105 of 3039

JAGUAR XFR 2010 1.G Workshop Manual
Pre-Terminated Wiring Harness(s)

The illustration shows:

The pre-terminated wiring harness(s

Page 2106 of 3039

JAGUAR XFR 2010 1.G Workshop Manual 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 gl

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 available. 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 available 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.

List of Parts

Description Part Number Quantity Pre-Terminated Wiring Harness(s) 418-066 to 418-103
inclusive 10 each 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 spacers 418-106 1 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 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 Harness repair components can be ordered from Jaguar/Land Rover authorised parts.

Repair Tools
The wiring harness repair tools comprises:
Crimping pliers
A wire cutter and insulation stripper
An electrical connector terminal extraction handle and tips
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 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.

Page 2107 of 3039

JAGUAR XFR 2010 1.G Workshop Manual Extraction Handle and Tips

Page 2108 of 3039

JAGUAR XFR 2010 1.G Workshop Manual Insulation Stripper

Page 2109 of 3039

JAGUAR XFR 2010 1.G Workshop Manual 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 41

Page 2110 of 3039

JAGUAR XFR 2010 1.G Workshop Manual 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 af

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 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. 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.

www.JagDocs.com

Page 2111 of 3039

Page 2112 of 3039

JAGUAR XFR 2010 1.G Workshop Manual ()_;
E130752

Load next 8 pages

Page: < prev 1-10 ... 2073-2080 2081-2088 2089-2096 2097-2104 2105-2112 2113-2120 2121-2128 2129-2136 2137-2144 ... 3040 next >

ESP inoperative bluetooth fuses suspension keyless wiper blades