LAND ROVER FRELANDER 2 2006 Repair Manual

Refer t o: Engi ne Upper Support Ins ulat or (303-01A Engine - I6 3.2LPetrol, Removal and Ins tall ati on).
Inst all both headlamps .
Refer t o: Headl amp As sembl y (417-01 Ext eri or Li ght ing, Removaland Inst all at ion).
49.
Inst all t he ABS module.
Refer t o: Ant i-Lock Brake Sys t em (ABS) Modul e (206-09A Anti -LockControl, Removal and Ins tall ati on).
50.
Inst all t he brake boost er.
Refer t o: Brake Boost er (206-07 Power Brake Act uat ion, Removaland Inst all at ion).
51.
Inst all t he s econdary bulkhead cent er panel.
Refer t o: Secondary Bulkhead Cent er Panel - I6 3.2L Pet rol (501-02Front End Body Panel s, Removal and Ins t al lat ion).
52.
Inst all t he air cleaner hous ing.
Refer t o: Air Cleaner (303-12A Intake Ai r Dis tribut ion and Fil tering -I6 3.2L Pet rol, Removal and Ins t al lat ion).
53.
Inst all t he bumper armature.
Refer t o: Front Bumper (501-19 Bumpers , Removal and Ins tall ati on).
54.

Publi s hed: 11-May-2011
Wiring Harnesses -
Torque SpecificationsDescriptionNmlb-ft
Cyli nder head ground65
Ground cables107W iri ng harnes s s upport bracket bolt s107

Publi s hed: 11-May-2011
Wiring Harnesses - Wiring Harness
Des cript ion and Operat ion
Introduction
CAUTION: Do not us e any ot her heat s hrink s l eeve ot her t han t he approved gl ue li ned heat s hri nk s leeve menti onedin the repai r procedure.
The purpos e of thi s document is to promote qui ck and efficient minor repai r to harnes s connect ors or cabl es usi ngapproved methods and t he wiring harnes s repai r ki t. Repairs may only be made t o cables and connectors which have beenmechani cal ly, not electrically damaged. It al s o appl ies where t he whol e extent of t he damage can be cl early ident ified andrect ifi ed.
Care and neat nes s are es sent ial requirement s i n making a perfect repair.
Caution:
At t he ti me of t his first i s sue of t he Harnes s Repair Guide, do not approve repairs to any of the followi ng circuit s :
Any media orient at ed s yst em trans port net work harnes s es .Suppl ement res traint s ys t em (SRS) firing ci rcuit s (Ai r bags ).Link l ead as s embles , which are unique t o s afety crit ical ci rcuit s s uch as ant i-lock brake s ys tem (ABS) andt hermocouple ci rcuit s . An exampl e of thi s is the ABS wheel s peed sens ors wi th moulded connectors.4. Screened cables , leads and wiring harnes s (s ).
If any harness(s) w ith defective electrical connector terminals or wires from the above circuits are a concern, newcomponents must be installed.
Repair Kit
CAUTION: W here t he repair procedure i ndi cat es t hat a glue l ined heat shrink s leeve shoul d be appli ed, applys ufficient heat t o t he glue l ined heat s hrink t o mel t t he glue i n order to provide a water t ight seal . Do not over heat theglue l ined heat s hrink s l eeve s o t hat the wiri ng harnes s ins ulat ion becomes damaged.
The wiring harnes s repai r kit has been produced whi ch compris es :
Pre-terminat ed wiring harnes s (s ) of different s izes and t ypesThree s izes of butt s pli ce connectorsA s electi on of col ored cable i dent ificati on s leevesTwo s izes of glue l ined heat s hrink s l eevesCri mping pl iersA wi re cut ter and i ns ulat ion s t ri pperAn elect rical connector t ermi nal extract ion handle and ti ps
A s uit able heat s ource, for shrinking heat s hrink sl eeves wi ll be requi red.
The pre-ins ulated di amond gri p range of electrical connect or terminal s and in-line, butt s pli ce connectors cont ai ned wit hint he wiring harnes s repai r ki t are t he only acceptable product for t he repai rs of wi ri ng harness es . The but t connectors notonly grip t he wi re but als o the i nsul at ion, making a very s ecure joi nt.
If an elect rical connect or t erminal is not included i n t he wiring harnes s repai r ki t then approval for t he repair i s NOT gi venand in thes e circums t ances a new wiring harnes s mus t be i ns t alled.
Pre-Terminated Wiring Harness(s) and Butt Splice Connectors
All pre-t ermi nat ed wiring harnes s (s ) and but t spl ice connectors in the wi ri ng harness repair kit are cont ained i n bags whichcan be res ealed after us e. Each bag i s marked wi th the part number of t he it ems s t ored wi thin the bag. Each st oragecompartment i n t he wiring harnes s repai r kit is identi fi ed wit h t he corres pondi ng part number. Make s ure thatpre-terminat ed wiring harnes s (s ) and connectors are not mixed up it is advis abl e t o only open one bag at a ti me and t ores eal the bag s ecurely before opening another bag. Al s o, replace the bag in i ts mati ng part number compartment wi thint he cas e.
The pre-terminat ed wiring harnes s (s ) are suppli ed wit h t he i ns ulat ion i n one of t hree colors , red, blue or yell ow. The col orsdo not appl y t o any part icular ci rcuit but t o t he harness wire s ize. See the Rel at ions hip Table in t he Repair Met hod secti on.
Butt s pli ce connect ors are al so suppli ed wit h red, bl ue or yel low coveri ngs , which mus t be mat ched to the pre-t ermi nat edwiring harnes s i nsul at ion col or.
Pre-Termi nat ed W i ri ng Harnes s(s )

The il lus trati on s hows :
The pre-terminat ed wiring harnes s (s ) which are included i n t he wiring harnes s repai r ki tThe part number of the pre-t ermi nat ed wi ri ng harnessThe let ter s howing t he extract or ti p which mus t be us ed t o remove this type of electrical connect or terminalThos e el ect ri cal connector t ermi nals whi ch are gold
Some of t he pre-terminated wiring harnes s(s ) have seals ins tal led t o t he ins ulati on for s ealed connect or appli cat ions . It i ses sent ial for preventi on of mois ture i ngress that a s ealed pre-t ermi nat ed wiring harnes s mus t be us ed where a s ealedt ermi nal was removed.
CAUTION: W here t he repair procedure i ndi cat es t hat a glue l ined heat shrink s leeve shoul d be appli ed, applys ufficient heat t o t he glue l ined heat s hrink t o mel t t he glue i n order to provide a water t ight seal . Do not over heat the

glue l ined heat s hrink s l eeve s o t hat the wiri ng harnes s ins ulat ion becomes damaged.
Two s izes of heat shrink s leeving are s uppl ied i n t he wiring harnes s repai r ki t. Each heat shrink s leeve cont ains a seal antglue. Thes e must be us ed when connect ing wi ri ng harness (s) or el ect ri cal connector termi nal (s ) at all t imes . The s mall erdiamet er heat s hri nk sl eeve is t o be us ed wi th the red and blue but t spl ice connectors and t he larger diamet er sl eeve wit ht he yel low but t s pl ice connect ors .
For eas e and s peed, s ome of t he pre-terminat ed wiring harnes s (s ) may al ready have the ins ul ati on part ly s t ripped at t hes plice end. If t he repai r requires ins ul ati on to be s tripped from the cable, refer to the Relat ions hip Table for the correctlength of ins ul ati on to be s tripped.
The Pre-Termi nat ed W i ri ng Harnes s(s ) il lus trati on shows t he elect rical connector t ermi nal t ype, t he part number of thepre-terminat ed wiring harnes s and t he let ter of t he ext ractor t ip which mus t be us ed to ext ract t he elect rical connect ort ermi nal from the connect or hous ing. Addi ti onal ly, t hos e el ect ri cal connector t ermi nal (s ) which are gold are i dent ified, allothers are t herefore, ti nned and not gold.
W i ri ng Harnes s Cabl e Ident ificati on Sleeves
A s electi on of col ored s leeves are cont ai ned in the wi ri ng harness repair kit for maint ai ning t he wi ring harnes s cableidenti fi cat ion on the pre-t ermi nat ed wi ri ng harness . Place t he correct col ored s l eeve(s ) over the pre-t ermi nat ed wi ri ngharnes s ins ulati on as near to the el ect ri cal connector as pos si ble wi th the main wi ri ng harness cable col or neares t t o t heelectrical connect or.
For example, i f the original wi ring harnes s cable color i s pink wi th a black t race put the pi nk wiring harnes s cableidenti fi cat ion s l eeve on the pre-t ermi nat ed wi ring harnes s firs t foll owed by a bl ack s l eeve, and s lide bot h along t he wi ri ngharnes s cabl e to the el ect ri cal connector t ermi nal.
Extraction Handle and Tips
The extract ion handle, in conjuncti on wit h t he correct t ip, is used t o remove a t ermi nal from an electrical connect or. Eacht ip contained i n t he wiring harnes s repai r kit is marked wi th an identi fi cat ion l etter, A t o K inclus ive. Each t ip has beens pecial ly des igned t o extract a parti cul ar t ype of electrical connect or terminal. The us e of any other t ool i s notrecommended and is liabl e to caus e damage t o t he electrical connect or. The t ip i s fas t ened to t he handle by a screw whichholds t he ti p firmly yet all ows it to be eas il y repl aced.
Extract ion Handle and Ti ps
Insulation Stripper
The moving jaw has an adjus t er wheel which has a series of holes i n it . Turning the wheel and placing t he cabl e in themat chi ng si ze hole wi ll automat icall y adjus t the jaw t o t he correct pres s ure. Note that s ome wi ri ng harness (s ) may have aharder ins ulati on and s li ght adjus t ment of the wheel may be needed to make a clean st ri p but exerci se care not to damaget he wire.
Ins ulat ion St ri pper

By pres s ing t he outer edges of the wi ri ng harnes s cabl e length st op t oget her the adjus t er can be s l id up or down t he jaw.This decreas es or i ncreases t he l engt h by which t he wi ri ng harness cable ins ul ati on wil l be s tripped from thepre-terminat ed wiring harnes s or wiring harnes s wi re. The adjus t er has a pos it ion indicator t o ali gn wit h a graduat ed s cal eand t hi s s ets t he correct l engt h i n mi lli metres , of i nsul at ion to be st ripped. The amount of ins ulati on t o be s tripped i ss hown in the Relat ions hip Table.
The il lus trati on s hows the i nsul at ion st ri pper t ool and a wiring harnes s correct ly gripped i n the jaws . A wi re cut ter isprovided on t he outer s ide of t he fixed jaw.
Cable Correctl y Gri pped in St ri pper Blades
Crimping Pliers
Cri mping Pl iers

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 dot which corresponds t o t he three col ours of t he pre-t erminatedwiring harnes s (s ) and but t spl ice connector colors .
List of Parts
DescriptionPart NumberQuantity
W iri ng Harnes s Repai r Kit418-S0651Pre-Termi nat ed W iri ng Harnes s (s )418-066 t o 418-103i ncl us i ve10 each
Gl ue Li ned Heat Shrink Pack – s mall di ameter418-10425 perpack
Gl ue Li ned Heat Shrink Pack – l arger di ameter418-10510 perpack
Cas e As sembl y Compri si ng – carry case, l id, inner li d, bas e, ins ert , trays foams pacers418-1061
Butt Spl ice Connect or – Red418-10750 perpackButt Spl ice Connect or – Blue418-10850 perpackButt Spl ice Connect or – Y el low418-10920 perpack
Extract ion Tool Handl e418-1101Extract ion Ti p Pack cons is ts of 2 s pare s crews plus418-S1111
Tip A418-1181
Tip B418-1191Tip C418-1201
Tip D418-1211
Tip E418-1221Tip F418-1231
Tip G418-1241
Tip H418-1251Tip I418-1261
Tip J418-1271
Tip K418-1281Sleeve Ident ificati on Pack – for Red i ns ulat ion418-112500
Sleeve Ident ificati on Pack – for Blue ins ul ati on418-113500
Sleeve Ident ificati on Pack – for Y ell ow ins ulat ion418-114500Inst ructi on ManualJTP 5931
Crimping Pl iersY RW 5000101
W ire Stripping Tool418-1171Items can be ordered from:
SPX Unit ed Kingdom Li mit ed

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.