Harness Repairs

Introduction
Two Land Rover harness repair kits are available. Range Rover (LM) harness repairs can be carried out using repair kit LRT-86-010. Range Rover (LP), Discovery Series II, and Freelander (01MY onwards) are covered by Harness Repair Kit LRT-86-010/1.

The Harness Repair Kits contain the following components to enable the technician to carry out 'Right First Time' repairs:
- Crimping pliers.
- Wire cutter/stripping tool.
- Heat shrink tubing.
- Wire colour identification rings.
- Splice connectors.
- Pre-terminated leads (connector pins with 90 mm wire 'pig tails').
- Connector housings.
- Connector pin extractor tools.

NOTE: Replacement connector housings and pre-terminated leads can be ordered from: SPX UK Ltd, Genoa House, Everdon Park, Daventry, Northants, NN11 5YJ. Tel: +44 (0)1327 303400

In order to carry out a repair, a suitable hot air gun and heat resistant blanket will also be required. These can be sourced locally.

The kits can be used to make repairs to all except the following:
- Any Media Orientated System Transport (MOST) network harnesses.
- Supplementary Restraint System (SRS) firing circuits.
- ABS wheel speed sensors with moulded connectors (Defender, Discovery Series II, and pre-02 MY Freelanders only).
- Any wires with a Cross Sectional Area (CSA) of greater than 4.0 mm.

If damage occurs in any of these areas, an overlay harness must be used.

WARNING: Repairs should only be carried out on wires that have been mechanically damaged, not electrically damaged (overheated/burned)

Repair Guidelines
The Harness Repair Kit includes an illustrated instruction booklet. However, there are additional repair guidelines that should be adhered to.

Twisted Pairs
Twisted pairs of wires (CAN bus, ABS wiring, etc.) can be repaired as required. When repairing a twisted pair of wires do not unwind the existing wires any more than necessary. Before completing the repair, replicate as closely as possible the original twisting pattern on any new wiring.

Splice Connectors
Whenever a repair is required, the position of the splice connectors must be staggered as follows:
- Small (red) and medium (blue) splice connectors = 40 mm stagger.
- Large (yellow) splice connectors = 50 mm stagger.

This keeps the bulk of the repaired area to a minimum, ensuring all trim etc. can be refitted correctly after the repair has been effected.

NOTE: Do not make more than 5 repairs per connector. If more than 5 wires are damaged, a part harness must be used to carry out the repair.

Replacement Connectors
If a connector is damaged and needs replacing, use the tools contained in the Harness Repair Kit to relocate the wires into the replacement connector. Only relocate one wire at a time, ensuring it is fitted to the correct cavity in the new connector.

Gold Connector Pins
A number of connector pins on the vehicle are gold plated. When a repair is required, these must be replaced by gold connector pins. Do not replace gold connector pins with tin connector pins as this will lead to early failure of the electrical contact.

Sealed Terminals
A number of terminals on the vehicle are sealed. When a repair is required, these must be replaced by a sealed terminal. An unsealed terminal fitted in place of a sealed terminal will result in early failure of the electrical contact.

Repair Methods
The following process should be used when carrying out a repair:

CAUTION: Before starting any work, ensure the vehicle battery has been disconnected. Work must not start on the vehicle for a further ten minutes.

This allows the SRS and Satellite Navigation systems time to de-energise.
1. Using the cutter/stripping tool, cut the wire to be repaired and strip the required amount of insulation from the wire.
2. Slide an appropriately sized heat shrink sleeve over the bare end wire for later fitment.
3. Remove the damaged connector pin from the connector housing using the appropriate extraction tools.
4. Select the correct connector pin pre-terminated lead and fit the appropriate wire colour identification rings.
5. Select the correct size of splice connector from the kit.
6. Using the crimping tool, crimp the splice connector to the harness bare end wire. The crimping tool contains three sets of jaws for crimping the splices. The jaw colours correspond to the splice connector colour.

CAUTION: The crimping tool jaws perform two different crimps simultaneously. One crimps the wire insulation, one crimps the bare wire. Ensure the splice connector is placed correctly in the crimping tool or the wire will be insufficiently crimped and a poor electrical contact may result.

7. Using the crimping tool, crimp the pre-terminated lead to the splice connector.
8. Slide the previously fitted heat shrink sleeve into position over the splice connector. Using the hot air gun to the manufacturers guidelines, apply heat evenly to the heat shrink tubing until it is tightly shrunk around the splice connector.

CAUTION:
- Place the asbestos blanket in a suitable position to avoid heat damage to adjacent components and trim.
- Do not overheat the repair as degradation and subsequent failure of the connection may result.

9. Connect the repaired wire to the connector housing.
10. Repeat steps 1 to 9 for any further damaged wires.