Terminated Wire Harnesses and Butt Connectors (Freelander 2)

All Terminated Wire Harnesses and Butt Connectors in the Harness Repair Kit are stored in bags that can be resealed after use. Each bag is labeled with the number of the parts stored in the bag. Each storage compartment in the harness repair kit is labeled with the appropriate part number. Make sure that the terminated wire harnesses and connectors are not mixed up: it is recommended to open one bag at a time and reseal the bag before opening the next one. Also, place the bag in the compartment of the case with the corresponding part number.

Terminated wire harnesses are available with one of three colors of insulation - red, blue or yellow. The colors do not refer to a specific circuit, but indicate the size of the wire in the bundle. See the mapping table in the Repair Method section.

Butt connectors are also available in red, blue and yellow to match the insulation color of the terminated wire harness.

Terminated wiring harness

The figure shows:

• Terminated Wire Harnesses Included in Wire Harness Repair Kit
• Terminated Wire Harness Part Number
• Letter indicating the extractor tip to be used to remove this type of contact from the electrical connector
• Gold Plated Electrical Connector Contacts

Some terminated wire harnesses have seals that are installed on the insulation for use where a sealed connector is required. If the sealed contact has been removed, a sealed, terminated wiring harness must be used to prevent moisture ingress.

CAUTION: If the repair procedure calls for the use of an adhesive heat shrink sleeve, heat the sleeve to the melting temperature of the adhesive to seal the seal. Do not overheat the adhesive heat shrink sleeve to avoid damage to the wire harness insulation.

The harness repair kit includes two sizes of heat shrink sleeves. Each shrink sleeve contains a sealing adhesive. These sleeves must always be used when connecting wire harnesses or electrical connector pins. The smaller diameter shrink sleeve is used with red and blue butt connectors, while the larger diameter sleeve is used with yellow butt connectors.

To simplify and speed up the procedure, some terminated wire harnesses may already be partially stripped at the splice side. If it is necessary to strip the insulation on the cable for repair, see the comparison table for the length of the insulation to be stripped.

On the image "Terminated wiring harness" shows the type of electrical connector pin, the part number of the terminated wire harness, and the letter of the extractor tip that should be used to remove the pin from the connector housing. In addition, the gold-plated contacts of the electrical connector are marked, all the rest are not gold-plated, but tinned.

Identification Sleeves for Cable Harnesses

The harness repair kit contains several colored sleeves to keep the identification of the harness cables in the terminated harness. Slide the correct color sleeve over the terminated harness insulation as close to the electrical connector as possible so that the base color of the harness cable is closest to the electrical connector.

For example, if the color of the original harness cable is pink with a black line, put the pink harness cable identification sleeve over the terminated harness, then put on the black sleeve after that, and slide both sleeves along the harness cable to the electrical connector terminal.