Defender Electric Diagrams. Manual — part 174

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Wire Chart (Pin-out table) – A six column table, giving details of each wire within the connector:

1. Cav: The connector pin (cavity) number.

NOTE: Wires may not be fitted to all cavities.

2. Terminal: Part number of the pin.

NOTE: Some wires do not have terminals, for example: antennae.

3. CSA: The cross sectional area of the wire in mm².
4. Col: The colour of wire populating the connector pin.
5. Cct: Identifies the model or option which uses the wire. 'ALL' means applicable to all models in the

range fitted with the feature or system in question. In instances where different models, features or
systems require different colour wires to be fitted in a cavity, each instance of the cavity is included in
the pin-out table.

6. Destn: The destination of the wire.

Sample wire chart – 6 pin connector

Cav Terminal CSA Col Cct Destn

1

AFU3728 4.50 N

2

C0571-3

1

AFU3728 4.50 N

6

C0571-5

2

AFU3725 3.00 NW 6

C0588-6

2

AFU3725 3.00 NW 2

C0588-2

3

AFU3728 4.50 NR 2

C0571-3

3

AFU3728 4.50 NR 6

C0571-3

4

AFU3725 3.00 WR 6

C0588-4

4

AFU3725 3.00 WR 2

C0588-4

6

AFU3725 2.50 SU 6

C0588-6

6

AFU3725 2.50 SU 2

C0588-3

HARNESS REPAIRS

Introduction

CAUTION: The harness must be replaced when the damage is attributed to excessive current flow or
where there is evidence of over-heating.

Never attempt to repair the following:

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Any connector terminal.

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Any Media Orientated System Transport (MOST) network harnesses.

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Supplemental Restraint System (SRS) firing circuits.

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Link lead assemblies, which are unique to safety critical areas such as ABS and thermocouple circuits;
a typical example is the ABS wheel speed sensor with moulded connector.

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Any wires with a cross sectional area (CSA) greater than 6.0mm.

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Screened cables and leads.

If damage occurs to any of the above areas, an overlay harness must be used. These are available through
the normal parts ordering process.

Repair Kit

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Crimping tool.

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Wire cutter/stripper.

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Heat-shrink sleeving.

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Wire colour identification rings.

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Splice connectors.

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Pre-terminated leads (connector pins with 90mm wire 'pig tails').

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Connector housings.

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Connector pin extractor tools.

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).

Part Harnesses

In addition to the items included in the harness repair kits, part harnesses are also available to effect repairs
on the vehicle. These part harnesses can be viewed via 'Microcat' and are available through the normal parts
ordering process.

Repair Guidelines

The Harness Repair Kit includes an illustrated instruction booklet, however the following additional repair
guidelines must be followed:

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

It is undesirable to make more than five repair joints on the wiring to any harness connector, where more
repairs are required at the same connector, the harness should be replaced.

Whenever a repair is required, the position of the splice connectors must be staggered. This keeps the bulk of
the repaired area to a minimum, ensuring all trim can be refitted correctly after the repair has been effected.

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 vehicle connectors are fitted with gold plated pins. Do not replace gold connector pins with tin
connector pins as this will lead to early failure of the electrical contact.

Repair Methods

CAUTION: Before commencing a repair, disconnect the vehicle battery and wait one minute to allow
the SRS and Satellite Navigation systems time to de-energise.

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

NOTE: Before commencing a repair, refer to the appropriate 'Service Repair Kit' table (see example in
Table 1 below) for details of the correct tools and replacement components. The 'Service Repair Kit'
table (where appropriate) can be found beneath the 'Connector Details' in the Electrical Reference
Library (ERL).

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

1. Using the wire cutter/stripper, 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 use.
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.

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
tool or the wire will be insufficiently crimped and a poor electrical contact may result.

6. The crimping tool contains three sets of jaws. The jaw colours correspond to the splice connector

YPL101910

0.75 CSA

Cavities 1-9, 11-15

VDK500010

Instruction, repair kit

1

VDK500070

Instruction, extract tool

1

VDK500080

Instruction, extract tool

1

YMI000870

Pre-terminated lead

1

YPQ000100

Identification rings (small)

1

YRV000040

Splice (red, CSA; 0.25-1.6) 1

YRW000390

Wire cutter/stripper

1

YRW500010

Applicator

1

YRW500060

Extract tool

1

YRW500070

Extract tool

1

colour. Select the correct jaw and crimp the splice connector to the harness bare-end wire.

7. Using the tool, crimp the pre-terminated lead to the splice connector.

CAUTION: Place the heat resistant blanket in a suitable position to avoid heat damage to
adjacent components and trim.

CAUTION: Do not overheat the repair as degradation and subsequent failure of the connection
may result.

8. Slide the previously fitted heat shrink sleeve into position over the splice connector. Using the hot-air

gun to the manufacturer's guidelines, apply heat evenly to the heat shrink sleeve until it is tightly shrunk
around the splice connector.

9. Connect the repaired wire to the connector housing.

10. Repeat steps 1 to 9 for any further damaged wires.