Land Rover Freelander 2004my Electrical Library Rover Manual
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INTRODUCTION 1.6FREELANDER 04MY 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 FREELANDER 04MY 1.7 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 1.8FREELANDER 04MY ABBREVIATIONS General AAmpere ABS Anti-lock braking system ac Alternating current A/C Air Conditioning ATF Automatic transmission fluid BUS Databus CAN Controller area network Cav Cavity Cct Circuit CCU Central control unit CDL Central door locking CHMSL Centre high mounted stop lamp Col Colour dc Direct current DCU Diagnostic control unit EAT Electronic automatic transmission EBD Electronic braking force distribution ECM Engine control module ECT Engine coolant temperature ECU Electronic control unit EKA Emergency key access ETC Electronic traction control FFuse FL Fusible link HDC Hill descent control HFS Heated front screen HRW Heated rear window HT High tension ISO International Organisation for Standardisation LED Light emitting diode LH Left hand LHD Left hand drive MIL Malfunction indicator lamp MOST Media Orientated System Transport NAS North American specification PTC Positive Temperature Co-efficient
INTRODUCTION FREELANDER 04MY 1.9 PWM Pulse width modulated RRelay RF Radio frequency RH Right hand RHD Right hand drive ROW Rest of world SRS Supplementary restraint system VVolt VIN Vehicle identification number WWatt
INTRODUCTION 1.10FREELANDER 04MY 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. 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 into 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:
INTRODUCTION FREELANDER 04MY 1.11 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. Example – 12 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. CavColCct 1GR ALL 2B ALL CavColCct 2G ALL 4GW 8 4GB 10 4GR 12 5LGB ALL 6GB 8 6GW 10 6GR 12 8B ALL CctModel or Feature 13 Door 25 Door 3LHD 4 RHD 5 Japanese vehicles only 6 NAS vehicles only 7 Australian vehicles only
INTRODUCTION 1.12FREELANDER 04MY 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. Using the marker pen supplied (or other suitable non-permanent marker pen), mark the parts of the circuit you have verified. 6. Continue to the next point on the circuit which is easiest to access and repeat the above. 7. Continue with 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 FREELANDER 04MY 1.13 WIRE COLOUR CODES General The following list contains wire colour codes used on the vehicle harnesss. CodeColour BBlack GGreen KPink LG Light green NBrown O Orange P Purple RRed S Slate (Grey) T Transparent UBlue WWhite Y Yellow
FUSE DETAILS FREELANDER 04MY 2.1 F USE DETAILSIntroduction Fuses are mounted in one of two fuse boxes. One fuse box is located in the LH rear side of the engine compartment, and the other is located behind the driver side cubby box. The engine compartment fuse box contains three different types of fuse: 1.Blade type fuse – Small, pull out, male fuse, used to protect circuits from 5 A to 30 A. 2.J–case fuse – Square shaped, pull out, female fuse, used to protect circuits from 30 A to 60 A. 3.Bolt down fuse – Also known as a fusible link, used to protect circuits from 40 A to 150 A. The passenger compartment fuse box contains blade type fuses only. WARNING: Contained within the passenger compartment fuse box is the SRS fuse. This is identified on the fuse box cover by a yellow label. Do not carry out any work on the SRS system before reading the SRS warnings, cautions, and notes contained within the Introduction section of the Workshop manual.