Land Rover Discovery 99my To 03my Electrical Library 3rd Edition Rover Manual

							INTRODUCTION
1.6DISCOVERY SERIES II
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: 
zCrimping pliers.
zWire cutter/stripping tool.
zHeat shrink tubing.
zWire colour identification rings.
zSplice connectors.
zPre-terminated leads (connector pins with 90mm wire pig tails).
zConnector housings.
zConnector 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:
zAny Media Orientated System Transport (MOST) network harnesses.
zSupplementary Restraint System (SRS) firing circuits.
zABS wheel speed sensors with moulded connectors (Defender, Discovery Series II, 
and pre-02MY Freelanders only).
zAny wires with a Cross Sectional Area (CSA) of greater than 4.0mm.
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) 
						

							INTRODUCTION
DISCOVERY SERIES II 1.7
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:
zSmall (red) and medium (blue) splice connectors = 40mm stagger.
zLarge (yellow) splice connectors = 50mm 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. 
						

							INTRODUCTION
1.8DISCOVERY SERIES II
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.
CAUTION: 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. 
						

							INTRODUCTION
DISCOVERY SERIES II 1.9
ABBREVIATIONS
General
AAmpere
AAT Ambient Air Temperature
ac Alternating current
ABS Anti-lock Braking System
A/C Air Conditioning
ACE Active Cornering Enhancement
ATC Automatic Temperature Control
BBUS Battery Backed-Up Sounder
BCU Body Control Unit
Cav Cavity
Cct Circuit
CDL Central Door Locking
CKP Crankshaft Position
CMP Camshaft Position
Col Colour
db Decibels
dc Direct Current
DCU Diagnostic Control Unit
EAT Electronic Automatic Transmission
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EGR Exhaust Gas Recirculation
EKA Emergency Key Access
FFuse
FBH Fuel Burning Heater
FL Fusible Link
HCT Heater Coolant Temperature
HDC Hill Descent Control
HFS Heated Front Screen
HO2S Heated Oxygen Sensor
HRW Heated Rear Window
ht High Tension
IACV Inlet Air Control Valve
ICE In-Car Entertainment
IDM Intelligent Driver Module 
						

							INTRODUCTION
1.10DISCOVERY SERIES II
ISO International Organisation for Standardization
LEVs Low Emission Vehicles
LH Left Hand
LHD Left Hand Drive
NAS North American Specification
PDC Park Distance Control
RH Right Hand
RHD Right Hand Drive
ROW Rest of World
SAI Secondary Air Injection
SLABS Self Levelling/Anti-Lock Braking System
SPE Single Point Entry
SRS Supplementary Restraint System
VVolt
VIN Vehicle Identification Number
W Watts 
						

							INTRODUCTION
DISCOVERY SERIES II 1.11
HOW TO USE THIS DOCUMENT
Fuse details
Contains information on fuse functions and values and should be used together with the 
power distribution circuit diagrams to establish which systems share a common power 
supply and to ensure that correct value fuses are fitted.
Earth points and headers
Shows a plan view of the vehicle with location of all earth points. Supporting photographs 
and connector detail information appear in the Connector section.
Description and Operation
Presented in the same order as the circuit diagrams in the Electrical Circuit Diagram folder, 
each of the descriptions contains a brief overview of the main system functions and includes 
reference to the appropriate wire colours. Always read this section before starting work on 
a system so that a good understanding of system functionality is obtained.
Each electrical item uses a description common on the circuit diagrams and the connector 
details. 
						

							INTRODUCTION
1.12DISCOVERY SERIES II
Connector Details
This section is effectively an index of every electrical connector on the vehicle, including 
headers and eyelets. A page is dedicated to each connector, with the information presented 
in a standard format. The connector number is displayed on each page header to ease 
reference. Connector information comprises:
zConnector Number – The assigned number, prefixed C
zConnector Name – Usually derived from the component to which the connection is 
made.
zMale/Female – If applicable, identifies the gender of the connector pins (NOT the 
housing) as Male or Female. Generally, connectors mating directly to a component 
have Female pins.
zColour – If applicable, the colour of the connector housing is shown. NATURAL is used 
to describe connectors with a clear/translucent plastic finish.
zLocation Statement – Used in conjunction with the photograph to determine the 
location of the connector.
zPhotograph – Shows the location of the subject connector. In most cases, the 
photograph will indicate the amount of trim removal necessary to reveal the connector. 
For convenience some photographs identify more than one connector.
zFace View – An outline of the connector housing, viewed from the front, showing pin 
numbers (if applicable).
zPin-out Table – A three column table, detailing the colour and position of each wire in 
the connector:
1.Cav:  The connector pin (cavity) number.
2.Col:  The colour of wire populating the connector pin.
3.Cct:  Identifies the model or feature 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.
NOTE: Wires may not be fitted to all cavities.Cav Col Cct
1GRALL
2BALL 
						

							INTRODUCTION
DISCOVERY SERIES II 1.13
Example – 9 pin connector
Where necessary a table listing the circuit reference numbers against a description of the 
model or features which may or may not be fitted, can be found at the beginning of the 
Connector section. A sample of a typical table is shown below:Cav Col Cct
2GALL
4GW7
4GB79
4GW90
5LGBALL
6GB7
6GW79
6GB80
8BALL
Cct Model or Feature
1 Premium ICE
2 Non Premium ICE
3Diesel
4Diesel Auto
5V8
6V8 Auto
7 Power Seats 
						

							INTRODUCTION
1.14DISCOVERY SERIES II
FAULT DIAGNOSIS
General
When diagnosing an electrical fault follow the steps below:
1. Read the circuit description appropriate to the reported fault to ensure a good 
understanding of circuit operation.
2. Study the power distribution, fuse details and earth distribution diagrams and identify 
other circuits which share fuses and/or earth points. Check whether these circuits 
operate correctly.
3. Using the photographs contained in the Connector section, locate a point on the circuit 
(approximately half way between supply and earth) which is easily accessible.
4. Check that the pin out details of the connector are correct and that the correct signals 
exist at the correct terminals.
5. Continue to the next point on the circuit which is easiest to access and repeat the 
above.
6. Continue this approach until a fault is found, rectify the fault and then verify that the 
circuit operates correctly.
CAUTION: Never probe directly into the front face of a connector. This can damage 
the terminal and cause a failure. Always probe the back of a terminal, taking care not 
to damage the terminal or any seals.
Never probe wire insulation. On small diameter cables this can cut the conductors. It 
may also allow moisture into the cable, causing corrosion. 
						

							INTRODUCTION
DISCOVERY SERIES II 1.15
WIRE COLOUR CODES
General
The following list contains the wire colour codes used on the vehicle harnesses.
Code Colour
BBlack
GGreen
KPink
LG Light green
NBrown
O Orange
P Purple
RRed
S Slate (Grey)
T Transparent
UBlue
WWhite
Y Yellow