Land Rover Defender: Wiring Harness - Approved Probing and Repair Methods, Electrical Connector Probing

APPROVED PROBING AND REPAIR METHODS

The purpose of this document is to identify the approved methods to promote an effective and efficient diagnosis and minor repair to the:

• Permitted electrical wiring harnesses, connectors and cables
  • See Electrical Wiring Harness Repair.
• Media Oriented System Transport (MOST) network harnesses, connectors and fiber optic cables
  • See MOST Network Harness Repair.

REPLACEMENT REPAIR EQUIPMENT

The repair processes in the following information identifies specific repair equipment needed to complete a repair to the required standard.

Replacement repair equipment can be ordered from the equipment workshop website: http://jlrequipment.service-solutions.com

ELECTRICAL CONNECTOR PROBING

Only 2 methods of electrical connector probing are allowed.

Method 1. Probing at the rear of unsealed electrical connectors (see illustration E190832).

Method 2. Probing on the conductor crimp of an extracted terminal (see illustration E190928).

• The conductor crimp is the portion crimped to the non-insulated wire.
• This method may be used on sealed or unsealed connectors, but method 1 is preferred for unsealed connectors.

CAUTIONS:

• A suitable sized probe must be used. If the probe is larger than the electrical connector aperture, then damage to the electrical connector will occur.
• The probe must only be inserted into the rear of the electrical connector for a distance sufficient to contact the terminal.
• Take care not to bend or distort any part of the metal terminal wire crimp area with the probe.
• Before extracting any terminals, refer to the Electrical Connector Terminal Extraction and Extraction Tools sections of this document for more information.
• Probing must not be done on: either the connector contact area or the portion of the terminal that is crimped to the insulated part of the wire.
• Make sure the terminal is correctly and securely located in the electrical connector after re-installation.

Method 1

Method 2

The following 2 methods of electrical connector probing are not allowed.

Method 1. Probing at the rear of sealed electrical connectors (see illustration E190926).

Method 2. Probing at the electrical connector contact area (see illustration E190927).

Method 1

Method 2

LIVE PROBING ON SEALED CONNECTORS

WARNINGS:

• This procedure must never be done on any of the following. Failure to follow this instruction may result in personal injury;
  • Supplementary Restraint System (SRS)
  • Pedestrian protection system
  • Throttle Control circuits
  • Speed Control circuits
  • Link lead assembles, which are unique to safety critical circuits such as Anti-Lock Brake System Control Module (ABS) and thermocouple circuits. An example of this is the ABS wheel speed sensors with molded connectors
• This procedure must only be done on wire with a cross sectional area of 0.5 mm squared or less.

CAUTIONS:

• The link lead used in this procedure must have a cross sectional area of at least 0.5 mm squared.
• The battery ground cable must be disconnected before any electrical connectors are disconnected / reconnected.

1. Disconnect the battery ground cable.
2. CAUTION: Before extracting any terminals, refer to the Electrical Connector Terminal Extraction and Extraction Tools sections of this document for more information.

Extract the terminal to be tested from the electrical connector

3. Insert a substitute wire with the same terminal and cross sectional area of the previously extracted wire, into the vacated position of the electrical connector.
4. CAUTION: The link lead clip must only be attached to the portion of the extracted terminal that is crimped directly to the section of non-insulated wire.

Attach 1 end of the link lead to the original wire terminal.

5. CAUTION: The link lead clip must only be attached to the non-insulated section of the wire.

Attach the remaining end of the link lead to the substitute wire.

6. Reconnect the electrical connector.
7. Reconnect the battery ground cable and begin the test.

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