ecu JAGUAR XFR 2010 1.G Workshop Manual

15 Xenon igniter unit and bulb 16 Xenon igniter electrical connector 17 Cornering/static bending lamp bulb (if fitted) 18 Side lamp bulb 19 High beam headlamp bulb 20 Cover - Side lamp, cornering/static bending lamp (if fitted) and high beam headlamp bulbs 21 Electrical connector Bi-Xenon Headlamp
The bi-xenon headlamp uses a projector lens, similar to the halogen headlamp. The projector module comprises an ellipsoidal
lens and a reflector. The projector reflector collects the light produced by the halogen bulb and projects the light into a focal
plane containing a shield. The contour of the shield is projected onto the road by the lens. A complex surface reflector is used
for the halogen fill in high beam lamp. This type of reflector is divided into separate parabolic segments, with each segment
having a different focal length. The low and high beam bulbs are quartz halogen H7, with a rating of 55W. The bulbs are
retained in the headlamp unit with conventional wire retaining clips.

A tourist lever mechanism is located on the right hand side of the projector module. This mechanism moves a flap to blank off
a portion of the beam spread to enable the vehicle to be driven in opposite drive hand markets without applying blanking
decals to the headlamp lens. The beam is changed by removing the access cover at the rear of the lamp assembly and moving
a small lever located near the bulb holder, at the side of the projector.


NOTE: The tourist lever is not fitted to NAS vehicles.


WARNING: The Xenon system generates up to 30000 volts and contact with this voltage could lead to fatality. Make sure
that the headlamps are switched off before working on the system.
The following safety precautions must be adhered to when working on the xenon low beam headlamp system:

DO NOT attempt any procedures on the xenon headlamps when the lights are switched on.
Handling of the D1S xenon bulb must be performed using suitable protective equipment; for example gloves and
goggles. The glass part of the bulb must not be touched.
Xenon bulbs must be disposed of as hazardous waste.
Only operate the bulb in a mounted condition in the projector module installed in the headlamp.

The xenon headlamp is known as 'bi-xenon' because it operates as both a low and high beam headlamp unit. The xenon lamp,
or High Intensity Discharge (HID) lamp as they are sometimes referred to, comprises an ellipsoidal lens with a solenoid
controlled shutter to change the beam output from low to high beam.


NOTE: If the lighting control switch is in the 'off' position, both the xenon lamp and the halogen high beam lamp will
operate when the high beam 'flash' function is operated.

The xenon headlamp system is controlled by the CJB using a control module for each headlamp and an igniter. The control modules and the igniters provide the regulated power supply required to illuminate the bulbs through their start-up phases of
operation.

The xenon headlamp is a self contained unit located within the headlamp assembly. The unit comprises a reflector, an adaptor
ring, the lens, a shutter controller and the xenon bulb, which together forms an assembly known as the projector module. The
reflector is curved and provides the mounting point for the xenon bulb. The bulb locates in a keyway to ensure the correct
alignment in the reflector and is secured by a plastic mounting ring. The bulb is an integral component of the igniter and is
electrically connected by a connector located in the igniter unit.

The shutter controller is a solenoid which operates the shutter mechanism via a lever. The shutter is used to change the beam
projection from low beam to high beam and vice versa.

The xenon bulbs illuminate when an arc of electrical current is established between 2 electrodes within the bulb. The xenon
gas sealed in the bulb reacts to the electrical excitation and the heat generated by the current flow to produce the
characteristic blue/white light.

To operate at full efficiency, the xenon bulb goes through 3 full stages of operation before full output for continuous operation
is achieved. The 3 phases are; start-up phase, warm-up phase and continuous phase.

In the start-up phase, the bulb requires an initial high voltage starting pulse of up to 30000 volts to establish the arc. This is
produced by the igniter. The warm-up phase begins once the arc is established. The xenon control module regulates the supply
to the bulb to 2.6A which gives a lamp output of 75W. During this phase, the xenon gas begins to illuminate brightly and the
environment within the bulb stabilizes, ensuring a continual current flow between the electrodes. When the warm-up phase is
complete, the xenon control module changes to continuous phase. The supply voltage to the bulb is reduced and the operating
power required for continual operation is reduced to 35W. The process from start-up to continuous phase is completed in a very
short time.

The xenon control modules (one per headlamp) receive an operating voltage from the CJB when the headlamps are switched on. The modules regulate the power supply required through the phases of start-up.

The igniters (one per headlamp) generate the initial high voltage required to establish the arc. The igniters have integral coils
which generate high voltage pulses required for start-up. Once the xenon bulbs are operating, the igniters provide a closed
circuit for the regulated power supply from the control modules.

dependant on a particular ignition mode status. The side lamps will also be illuminated when the lighting control switch is in
the AUTO position and a 'lights on' signal is received by the CJB from the rain/light sensor Side Marker Lamps (NAS only)

The side marker lamp is located in the outer part of the headlamp assembly. The side marker lamp uses a W5W wedge fitting
bulb. The bulb is fitted into a holder which connects with contacts in the headlamp housing. The holder is fitted into an
aperture which connects with contacts in the headlamp housing. The side marker lamp is active at all times when the side
lamps are active.

AUTOMATIC HEADLAMP OPERATION

The automatic headlamp function is a driver assistance system. The driver can override the system operation by selection of
side lamp or headlamp on if the ambient light conditions require front and rear lighting to be active. The automatic headlamp
system uses a light sensor and the CJB, which are connected via a LIN (local interconnect network) bus to control the headlamp functionality. The light sensor is incorporated in the rain/light sensor located on the inside of the windshield, below
the rear view mirror. The wiper system also uses the rain/light sensor for automatic wiper operation.

The light sensor measures the ambient light around the vehicle in a vertical direction and also the angular light level from the
front of the vehicle. The rain/light sensor uses vehicle speed signals, wiper switch position and the park position of the front
wipers to control the system. The automatic headlamp operation uses ambient light levels which are monitored by photodiode
incorporated in the rain/light sensor. The rain/light sensor sends a lights on/off request to the CJB on the LIN bus, which responds by switching on the low beam headlamps, front side lamps and rear tail lamps. The automatic headlamps are
activated under the following conditions:

Twilight
Darkness
Rain
Snow
Tunnels
Underground or multistoried car parks.

Operation of the automatic headlamps requires the ignition to be in ignition mode 6, the lighting control switch to be in the
'AUTO' position and a lights on request signal from the light sensor. If the rain sensor signal activates the fast speed wipers,
the low beam headlamps are activated, providing the lighting control switch is in the 'AUTO' position.

HEADLAMP LEVELING

Headlamp leveling provides for the adjustment of the vertical aim of the headlamps. The leveling system is primarily required
to minimise glare to other road users when a heavy load is in the rear of the vehicle. Two systems of headlamp leveling are
available; manual and static dynamic.
Manual Headlamp Leveling

The manual system uses a thumbwheel rheostat to adjust the vertical alignment of the headlamps to compensate for differing
vehicle loading. The rotary thumbwheel is located on the auxiliary lighting switch, adjacent to the illumination dimmer
thumbwheel. Three positions are available to adjust the headlamps to a position to prevent glare to other road users.
Static Dynamic Headlamp Leveling
The static dynamic headlamp leveling system uses the following components:
Front and rear vehicle height sensors
Two headlamp leveling, vertical adjustment motors
Headlamp leveling module
Ignition in mode 6
Vehicle speed information from ABS module.
The static dynamic system uses height sensors fitted to the front and rear suspension and a headlamp leveling module which
periodically monitors the vehicle attitude and adjusts the headlamp vertical alignment accordingly.

Static dynamic headlamp leveling is controlled by a headlamp leveling module located in the lower instrument panel, behind
the glovebox.

The height sensors are both located on the RH side of the vehicle. The front sensor is attached to the front suspension lower arm with a strap and to the front sub frame with a bracket and 2 bolts. The rear sensor is attached to the rear suspension
upper control arm with a cable tied clip and to the rear sub frame with a bracket and 2 bolts. Each sensor has 3 connections to
the headlamp leveling module; power, ground and signal.

DAYTIME RUNNING LAMPS (DRL)

Refer to DRL section for details. Refer to: Daytime Running Lamps (DRL) (417-04 Daytime Running Lamps (DRL), Description and Operation).
REAR LAMP ASSEMBLY

The rear lamp assembly is a 2 piece unit, with one part located in the rear quarter panel and the second part attached to the
luggage compartment lid. The outer rear lamp assembly is located in a recess in the vehicle body. The lamp is secured with 2
studs inboard studs on the lamp body which are secured to the vehicle body with 2 nuts. A third outboard stud and nut secures

1 Nut (3 off) 2 Reverse lamp bulb and holder 3 Rear lamp electrical connector 4 Turn signal indicator bulb and holder 5 Securing clip 6 Rear fog lamp electrical connector 7 Rear fog lamp LED's and Printed Circuit Board (PCB) 8 Side marker LED's (4 off - all markets) 9 Reverse lamp 10 Turn signal indicator lamp 11 Side lamp/stop lamp LED's (24 off) 12 Rear fog lamp LED's (3 off) Rear Stop and Side Lamp

The turn signal indicator, side and stop lamps and reverse lamps are located in each outer rear lamp assembly. The side lamps
and stop lamps use 24 LED's. The 24 LED's are illuminated at a higher intensity than the side lamp when the stop lamp switch is operated by pressing the brake pedal. A side marker lamp is fitted to the outer rear lamp assembly and is fitted in all
markets. The side marker lamp also uses 4 LED's and are active at all times when the side lamps are selected on.
The stop lamps can also be activated by the adaptive speed control system. A signal from the adaptive speed control module
is sent via the high speed CAN bus to the RJB which activates the stop lamps until an off message is received. Turn Signal Indicator

The turn signal indicator lamp uses a Phillips Hypervision glass filament bulb. The bulb is located in a holder which has
contacts which mate with contacts on lamp body. The holder locates in the lamp body and is rotated to lock.

If a bulb fails, the remaining turn signal indicator lamps continue to flash at the normal speed. The applicable turn signal
indicator in the instrument cluster will flash at double speed to indicate the bulb failure to the driver. www.JagDocs.com

Rear Fog Lamp

The rear fog lamps are located in separate units attached to the luggage compartment lid. The rear fog lamps each use 3 high
intensity LED's. The fog lamp locates in a recess in the luggage compartment lid has a seal to prevent the ingress of water into the luggage compartment. The lamp is secured in the recess with a metal securing clip. The rear fog lamp is activated
using a button located on the auxiliary lighting switch in the instrument panel.

LICENCE PLATE LAMPS

Two licence plate lamps are located in the luggage compartment lid trim finisher. One is located adjacent to the emergency
luggage compartment lid release key barrel cover and the other is adjacent to the rear view camera (if fitted). The licence plate
lamps are active at all times when the side lamps are operating. Each lamp can be removed from the finisher by inserting a
wide, flat screwdriver blade or similar tool in a slot between the lamp lens and the finisher and gently levering the lamp from
the surround. The bulb is a push fit in a holder which in turn is a press fit in the lamp housing.

HIGH MOUNTED STOP LAMP

The high mounted stop lamp is located at the bottom of the rear windshield. The lamp is secured to a bezel in the parcel shelf
with 2 screws.

The high mounted stop lamp uses 12, red colored LED's which illuminate through a clear lens. The high mounted stop lamp functionality is the same as that described for the stop lamps.

TURN SIGNAL INDICATOR SIDE REPEATER LAMPS

The turn signal indicator side repeaters are located in each door mirror. On vehicles from 10MY the lamp is an LED unit which illuminates in an orange color. The LED unit is secured to the mirror bezel with 2 screws and is connected to the mirror wiring harness with a 2 pin connector.

The side repeaters have the same functionality and operate in conjunction with the front and rear turn signal indicators and
the hazard warning flashers.

HAZARD FLASHERS

The hazard flashers are activated by a non-latching switch located in the switch pack located in the center of the instrument
panel. The hazard flashers operate at all times when selected and operate independent of the ignition mode.

When the hazard flashers are selected on by the driver, a ground path is momentarily completed to the CJB which activates the front and rear and side repeater turn signal indicators. A second press of the switch is sensed by the CJB and the hazard flasher are deactivated. When the hazard flashers are active, they override any request for turn signal indicator operation.
The hazard flashers can also be activated by a crash signal from the RCM. Refer to: Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, Description and Operation).

1 LH map reading lamp bulb 2 Interior lamp bulb 3 RH map reading lamp bulb 4 Printed Circuit Board (PCB) - JaguarSense 5 Ambience lighting LED's 6 RH map reading lamp 7 Interior lamp 8 LH map reading lamp The overhead console is located near the windshield in the head lining. The console can be removed by carefully levering out
the rear edge of the housing to release 2 spring clips, and then pulling the console rearwards to release 2 locating tabs.
Removal of the console is required to replace any of the interior or map reading lamp bulbs.

The interior lamps and air bag off warning lamp in the front overhead console are common to all vehicles. The overhead
console can also contain security system intrusion detection module and volumetric sensors, sunroof switch and a voice
activation microphone depending on vehicle specification and market.

The interior lamp can operated manually using the JaguarSense feature to switch the lamp on and off. The lamp is also
controlled as part of the automatic interior lighting system.
The map reading lamps only operate manually using the JaguarSense feature to activate the lamps.

The interior and map reading lamp bulbs are located in holders which locate in a PCB. The PCB also provides for the operation
of the ambience lighting LED's, the air bag off warning lamp and the JaguarSense proximity sensors which are integral with the PCB.

The overhead console also contains 2 LED's for the ambience lighting system. The ambience lighting is part of the lighting control switch functionality and is subject to the setting of the instrument panel illumination dimmer control in the auxiliary
lighting switch. The ambience lighting provides very limited illumination of the instrument panel and floor console when the
vehicle is being driven without affecting the driver's visibility. www.JagDocs.com

DTC Description Possible Cause Action B110011
O2 sensor heater
relay
FPDB O2 sensor heater relay
control circuit - short to ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check FPDB O2
sensor heater relay control circuit for short to ground B113D12
Sunroof Global
Open/Close Control
Roof opening panel global
open/close control circuit -
short to power Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check roof
opening panel global open/close control circuit for short
to power B113D14
Sunroof Global
Open/Close Control
Roof opening panel global
open/close control circuit -
short to ground, open circuit Refer to the electrical circuit diagrams and check roof
opening panel global open/close control circuit for short
to ground, open circuit B114011
Engine Crank
Authorisation
Engine crank authorisation
signal circuit - short to ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check engine
crank authorisation signal circuit for short to ground B114211 Ignition Status 1
Ignition supply 1 circuits -
short to ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check all ignition supply 1 circuits for short to ground B114311 Ignition Status 2
Ignition supply 2 circuits -
short to ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check all ignition supply 2 circuits for short to ground B114411
Heated Steering
Wheel Supply
Heated steering wheel supply
circuit - short to ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check heated steering wheel supply circuit for short to ground B114511
Glovebox Locking
Motor
Glovebox latch locking motor
circuit - short to ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check glovebox latch locking motor circuit for short to ground B114512
Glovebox Locking
Motor
Glovebox latch locking motor
control circuit - short to power Refer to the electrical circuit diagrams and check
glovebox latch locking motor control circuit for short to
power B114513
Glovebox Locking
Motor
Glovebox latch locking motor
control circuit - open circuit Refer to the electrical circuit diagrams and check
glovebox latch locking motor control circuit for open
circuit B114612
Passive sounder
Supply
Security passive sounder
control circuit - short to power Refer to the electrical circuit diagrams and check security
passive sounder control circuit for short to power B114614
Passive sounder
Supply
Security passive sounder
control circuit - short to ground,
open circuit Refer to the electrical circuit diagrams and check security
passive sounder control circuit for short to ground, open
circuit B115811
Front Passenger
Seat Heater Sensor
Front passenger seat heater
sensor circuit - short to ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check front passenger seat heater sensor circuit for short to ground B115813
Front Passenger
Seat Heater Sensor
Front passenger seat heater
sensor circuit - open circuit Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check front passenger seat heater sensor circuit for open circuit B115911
Driver Seat Heater
Sensor
Driver seat heater sensor
circuit - short to ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check driver
seat heater sensor circuit for short to ground B115913
Driver Seat Heater
Sensor
Driver seat heater sensor
circuit - open circuit Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check driver
seat heater sensor circuit for open circuit B115A11
Front Passenger
Seat Heater
Front passenger seat heater
supply circuit - short to ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check front passenger seat heater supply circuit for short to ground B115A15
Front Passenger
Seat Heater
Front passenger seat heater
supply circuit - short to power,
open circuit Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check front
passenger seat heater supply circuit for short to power, open circuit

DTC Description Possible Cause Action B1D2711
Heater Coolant
Pump
Heater coolant pump control
circuit - short to ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check heater
coolant pump control circuit for short to ground B1D2713
Heater Coolant
Pump
Heater coolant pump control
circuit - open circuit Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check heater
coolant pump control circuit for open circuit B1D9796 Tilt Sensor
Component internal failure Suspect the battery backed sounder, check and install a
new battery backed sounder as required P057112
Brake Switch A
Circuit
Footbrake switch circuit - short
to power Refer to the electrical circuit diagrams and check
footbrake switch circuit for short to power P080111
Reverse Inhibit
Control Circuit
Electrochromic rear view mirror,
reverse inhibit circuit - short to
ground Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check
electrochromic rear view mirror, reverse inhibit circuit for
short to ground P080112
Reverse Inhibit
Control Circuit
Electrochromic rear view mirror,
reverse inhibit circuit - short to
power Refer to the electrical circuit diagrams and check
electrochromic rear view mirror, reverse inhibit circuit for
short to power P080113
Reverse Inhibit
Control Circuit
Electrochromic rear view mirror,
reverse inhibit circuit - open
circuit Refer to the electrical circuit diagrams and check
electrochromic rear view mirror, reverse inhibit circuit for
open circuit P085013
Park/Neutral Switch
Input Circuit
Park/Neutral signal circuit -
open circuit Refer to the electrical circuit diagrams and check
Park/Neutral signal circuit for open circuit P162413 Anti-theft System
RJB anti-theft signal circuit -
open circuit Refer to the electrical circuit diagrams and check RJB
anti-theft signal circuit for open circuit P254F13
Engine Hood Switch
Circuit/Open
Hood ajar switch signal circuit -
open circuit Refer to the electrical circuit diagrams and check hood
ajar switch signal circuit for open circuit U001988
Low Speed CAN
Communication Bus
Bus OFF Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system. U014200
Lost
Communication
With Body Control
Module "B"
No sub type information Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system. U015500
Lost
Communication
With Instrument
Panel Cluster (IPC)
Control Module
No sub type information Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system. U015600
Lost
Communication
With Information
Center "A"
No sub type information Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system. U016400
Lost
Communication
With HVAC Control
Module
No sub type information Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system. U016800
Lost
Communication
With Vehicle
Security Control
Module
No sub type information Check power and ground supplies to vehicle security
module U019900
Lost
Communication
With "Door Control
Module A"
No sub type information Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system. U020000
Lost
Communication
With "Door Control
Module B"
No sub type information Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.

DTC Description Possible Cause Action U021400
Lost
Communication
With Remote
Function Actuation
No sub type information Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system. U023100
Lost
Communication
With Rain Sensing
Module
No sub type information Check power and ground supplies to rain sensing module.
LIN circuit fault U030000
Internal Control
Module Software Incompatibility
No sub type information Suspect the CJB. Check and install a new CJB as
required, refer to the new module/component installation
note at the top of the DTC Index U1000-00
Solid State Driver
Protection Active -
Driver Disabled -
No sub type
information
Central junction box output
circuit - Short circuit to ground,
short circuit to power
NOTE: The relevant output is disabled while this
DTC is set. Do not clear the DTC until the fault has been
rectified

Using the manufacturer approved diagnostic
system, check for other central junction box short
circuit to ground and/or short circuit to power
DTCs and refer to the relevant DTC index for
corrective actions
Once circuit faults have been rectified, clear DTC
and retest U1A1449
CAN Initialisation
Failure
Internal electronic failure Suspect the CJB. Check and install a new CJB as
required, refer to the new module/component installation
note at the top of the DTC Index U200813 Sensor Cluster
Instrument cluster security
signal circuit - open circuit Refer to the electrical circuit diagrams and check
instrument cluster security signal circuit for open circuit U201012 Switch Illumination
Switch/interior illumination
PWM supply circuit - short to
power Refer to the electrical circuit diagrams and check
switch/interior illumination PWM supply circuit for short
to power U201014 Switch Illumination
Switch/interior illumination
PWM supply circuit - short to
ground, open circuit Refer to the electrical circuit diagrams and check
switch/interior illumination PWM supply circuit for short
to ground, open circuit U210000
Initial Configuration
Not Complete
RJB configuration (parameters)
failure Re-configure the RJB using the manufacturer approved
diagnostic system U3000-49
Control Module -
Internal electronic
failure
Central junction box - Internal
failure
NOTE: The relevant output is disabled while this
DTC is set

Using the manufacturer approved diagnostic
system, check for other central junction box short
circuit to ground and/or short circuit to power
DTCs and refer to the relevant DTC index for
corrective actions
Install a new central junction box as required.
Clear DTCs and retest U300055 Control Module
Not configured Re-configure the RJB using the manufacturer approved
diagnostic system. Check the correct CJB is installed to
vehicle market/specification. Install a new/correct CJB as
required, refer to the new module/component installation
note at the top of the DTC Index U300087 Control Module
Missing message Carry out CAN network integrity test using the
manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check CAN network
between RJB and CJB for short, open circuit. Check RJB
and then CJB for related DTCs and refer to the relevant
DTC Index U300281
Vehicle
Identification
Number
Invalid serial data received Suspect the CJB has previously been installed to another
vehicle. Check and install the original or a new CJB U300317 Battery Voltage
Circuit voltage above threshold Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.

Wiring Harnesses - Wiring Harness
Description and Operation

Introduction Published: 21-Jan-2014

CAUTION: Do not use any other heat shrink sleeve other than the approved glue lined heat shrink sleeve mentioned in
the repair procedure.

The purpose of this document is to promote quick and efficient minor repair to harness connectors or cables using approved
methods. Repairs may only be made to cables and connectors which have been mechanically, not electrically damaged. It also
applies where the whole extent of the damage can be clearly identified and rectified.
Care and neatness are essential requirements in making a perfect repair.

Caution:

This harness repair guide, does not approve repairs to any of the following circuits:
1. Any media orientated system transport network harnesses.
2. Supplement restraint system (SRS) firing circuits (Air bags).
3. Link lead assembles, which are unique to safety critical circuits such as anti-lock brake system (ABS) and thermocouple
circuits. An example of this is the ABS wheel speed sensors with moulded connectors.
4. 4. Screened cables, leads and wiring harness(s).

If any harness(s) with defective electrical connector terminals or wires from the above circuits are a concern, new
components must be installed.

Repair Components


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.
The wiring harness repair components comprises:

Pre-terminated wiring harness(s) of different sizes and types
Three sizes of butt splice connectors
A selection of colored cable identification sleeves
Two sizes of glue lined heat shrink sleeves
A suitable heat source, for shrinking heat shrink sleeves will be required.

The pre-insulated diamond grip range of electrical connector terminals and in-line, butt splice connectors are the only
acceptable product for the repairs of wiring harnesses. The butt connectors not only grip the wire but also the insulation,
making a very secure joint.

If an electrical connector terminal is not available approval for the repair is NOT given and in these circumstances a new wiring
harness must be installed.

Pre-Terminated Wiring Harness(s) and Butt Splice Connectors

The pre-terminated wiring harness(s) are supplied with the insulation in one of three colors, red, blue or yellow. The colors do
not apply to any particular circuit but to the harness wire size. See the Relationship Table in the Repair Method section.

Butt splice connectors are also supplied with red, blue or yellow coverings, which must be matched to the pre-terminated
wiring harness insulation color.

length.

4.



5.
6.




7.





8.


9.




10.

11.

12.












13.


14.

15. 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 over tighten. 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 connector is securely held in the aperture. This will
give support to the butt connector while the pre-terminated wiring harness is inserted into it.

NOTE: See illustration: Splice Correctly Located

Insert the pre-terminated wiring harness 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 freed 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 harness(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 splice window over the guide bar. Make sure that the cable harness
wire is against 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 splice to make sure that a secure joint has been made.

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 until the fuel spill has fully evaporated.
CAUTIONS:


When using a heat source make sure that it is localised and causes 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 wiring harness insulation becomes damaged.
Using a suitable heat source, shrink the sleeve over the butt splice.
If further pre-terminated wiring harness(s) are to be installed to the same 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 harness 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 cover and secure with adhesive electrical tape. Do not cover the wiring harness right to the
electrical connector as the terminals must have a little movement and not 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.
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