JAGUAR X308 1998 2.G Workshop Manual

The illustration shows:
The pre-terminated wiring harness(s) which are included in the wiring harness repair kit

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
essential for prevention of mo isture ingress that a sealed pre-terminated wiring harness must be used where a sealed
terminal was removed.
CAUTION: Where the repair procedure indica tes 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 supplied in the wiring harn ess repair kit. 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 di ameter sleeve with
the yellow butt sp lice connectors.
For ease and speed, some of the pre-term inated wiring harness(s) may already have the insulation partly stripped at the
splice end. If the repair requires insula tion to be stripped from the cable, refer to the Relationship Table fo r the correct
length of insulation to be stripped.
The Pre-Terminated Wiring Harness(s) illu stration 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 conne ctor 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 contai ned in the wiring harness repair kit for maintaining the wiring harness cable
identification on the pre-term inated wiring harness. Place the correct colo red sleeve(s) over the pre-terminated wiring
harness insulation as near to the electr ical 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 electr ical connector terminal.
Extraction Handle and Tips
The extraction handle, in conjunction with th e correct tip, is used to remove a terminal from an elec trical connector. Each tip contained in the wiring harness repair kit is marked with an identification letter, A to K inclusive. Each tip has been special ly
designed to extract a particular ty pe 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
The moving jaw has an adjuster wheel which has a series of holes in it. Turning the wheel and placing the cable in the
matching size hole will automatically adjust the jaw to the correct pressure. Note that some wiring harness(s) may have a
harder insulation and slight adjustment of the wheel may be needed to make a clean strip but exercise care not to damage
the wire.
Insulation Stripper

By pressing the outer edges of the wiring harness cable length stop together the adjuster can be slid up or down the jaw.
This decreases or increases the length by which the wiring harn ess cable insulation will be stripped from the pre-terminated
wiring harness or wiring harness wire. The adjuster has a position indicator to align with a graduated scale and this sets the
correct length in millimet res, of insulation to be strippe d. The amount of insulation to be stripped is shown in the
Relationship Table.
The illustration shows the insulation stri pper tool and a wiring harness correctly gripped in the jaws. A wire cutter is
provided on the outer side of the fixed jaw.
Cable Correctly Grippe d in Stripper Blades

Crimping Pliers
Crimping Pliers

The crimping pliers have a moving jaw and a stationary jaw, with three different sized crimping enclosures. Each of the
enclosures is identified by a red, blue or yellow coloured dot which correspon ds to the three colours of the pre-terminated
wiring harness(s) and butt splice connector colors.
List of Parts
DescriptionPart NumberQuantity
Wiring Harness Repair Kit 418-S0651
Pre-Terminated Wiring Harness(s)418-066 to 418-103
inclusive 10 each
Glue Lined Heat Shrink Pack – small diameter418-10425 per
pack
Glue Lined Heat Shrink Pack – larger diameter418-10510 per pack
Case Assembly Comprising – carry case, li d, inner lid, base, insert, trays foam
spacers418-1061
Butt Splice Connector – Red 418-10750 per pack
Butt Splice Connector – Blue 418-10850 per
pack
Butt Splice Connector – Yellow 418-10920 per pack
Extraction Tool Handle 418-1101
Extraction Tip Pack consists of 2 spare screws plus 418-S1111
Tip A418-1181
Tip B418-1191
Tip C418-1201
Tip D418-1211
Tip E418-1221
Tip F418-1231

Items can be ordered from:
SPX United Kingdom Limited
Ironstone Way
Brixworth
Northants
NN6 9UD
United 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 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 th e quick identification of electrical connectors and faulty pin
terminal(s).
Reference can also be made to the vehicle Electrical Guides, he ld 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
Electrical Connector Terminal Extraction
Tip G418-1241
Tip H418-1251
Tip I418-1261
Tip J418-1271
Tip K418-1281
Sleeve Identification Pa ck – for Red insulation418-112500
Sleeve Identification Pack – for Blue insulation 418-113500
Sleeve Identification Pack – for Yellow insulation 418-114500
Instruction Manual JTP 5931
Crimping Pliers YRW5000101
Wire Stripping Tool 418-1171
CABLE RANGE SPLICE STRIP LENGTH
0.35 mm² to 1.50 mm²RED6.00 to 7.00 mm
1.00 mm² to 2.50 mm²BLUE6.00 to 7.00 mm
4.00 mm² to 6.00 mm²YELLOW9.00 to 9.50 mm

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 thes e 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 and these have been included in the kit. Most can be released by carefully using a
suitable small screwdriver.
Various types of electrical connector have seals installed intern ally 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 us ed on vehicles therefore only one example using each tip is shown. Technicians
experience and judgement will dictate whic h type of tip should be used for those electrical connector(s) which are not
shown. Care should be exercised to av oid further damage when removing the te rminals from the electrical connector.
• NOTE: Examples of the extraction tips and anti-backout tips.