JAGUAR XFR 2010 1.G Workshop Manual

Published: 11-May-2011
Module Communications Network - Auxiliary Junction Box (AJB)
Removal and Installation

Removal


NOTE: Removal steps in this procedure may contain installation details.

1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

2. Refer to: Loadspace Trim Panel RH (501-05 Interior Trim and Ornamentation, Removal and Installation).
3.
Installation

1. To install, reverse the removal procedure.

2. If a new component has been installed, configure using Jaguar approved
diagnostic equipment.

Module Communications Network - Central Junction Box (CJB)
Removal and Installation

Removal


NOTE: Removal steps in this procedure may contain installation details.

All vehicles Published: 11-May-2011

1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

2. Refer to: Cowl Side Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).

Left-hand drive vehicles

3.

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.

Pre-Terminated Wiring Harness(s)



















































The illustration shows:

The pre-terminated wiring harness(s) which are available via Jaguar/Land Rover authorised parts.
The part number of the pre-terminated wiring harness
The letter showing the extractor tip which must be used to remove this type of electrical connector terminal
Those electrical connector terminals which are gold
Some of the pre-terminated wiring harness(s) have seals installed to the insulation for sealed connector applications. It is www.JagDocs.com

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.

Extraction Handle and Tips

Insulation Stripper

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 418-124 1 Tip H 418-125 1 Tip I 418-126 1 Tip J 418-127 1 Tip K 418-128 1 Crimping Pliers YRW500010 1 Wire Stripping Tool 418-117 1 Harness repair tools can be ordered from:
Bosch Automotive Service Solutions
Ironstone Way
Brixworth Industrial Estate
Brixworth
Northants
NN6 9UD
United Kingdom

Telephone: +44 (0) 1327 303400
Fax: +44 (0) 1327 303499

Email: css.uk@bosch-automotive.com Crimping Pliers

Crimping Pliers

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.

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