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

All pre-terminated wiring harness(s) and butt splice connectors in the wiring harness repair kit are contained in bags which can be resealed after use. Each bag is marked with the part number of the items stored within the bag. Each storage compartment in the wiring harness repair kit is identified with the corresponding part number. Make sure that pre-terminated wiring harness(s) and connectors are not mixed up it is advisable to only open one bag at a time and to reseal the bag securely before opening another bag. Also, replace the bag in its mating part number compartment within the case.

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)

Courtesy of JAGUAR CARS, INC.

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 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 supplied in the wiring harness 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 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 contained in the wiring harness repair kit 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.