Battery - Discharges

418-08

DATE: 10/98
Amended: 02/02

MODEL:
1998-2002 MY V8 XJ Series

VIN:
812256-F40850

Discharged Battery - Modify Heated Windshield Harness - Canadian Vehicles Only

Remove and destroy Bulletin 418-08, dated 0210 Replace with this Bulletin.

This repair is no longer a service action (S692).

Service Action S692 is now closed.

Issue:
Some Canadian market V8 XJ Series vehicles within the above VIN range may experience corrosion in electrical connectors, located in the engine compartment, that supply power to the heated windshield. The corrosion is caused by water entering the wiring and being conducted by capillary action through the wire strands under the insulation. It is possible for this water not only to cause corrosion at the connectors within the 'cool boxes' immediately in front of the bulkhead, but the water may pass beyond the connectors and cause corrosion in the engine control module (ECM) wiring harness and related relays. This condition can result in a constant current draw that causes a discharged battery.

A harness modification has been introduced in production after VIN F40850, involving the use of improved wiring that incorporate water barriers.

This bulletin provides a modification procedure for vehicles equipped with the heated windshield option, within the above VIN range. The procedure involves replacing a short length of harness on each side of the vehicle by a harness that includes a "solder block" which acts as a barrier to water entry.

Action:
In case of a customer complaint of the above condition on a V8 XJ Series vehicle within the above VIN range, perform the following repair.

PROCEDURE

1. Disconnect the battery. Install protective fender covers.

2. Remove the bulkhead covers from both sides of the vehicle.

3. On one side, identify and release the cable and connector that leads to the heated windshield. (The connectors are located immediately to the rear of each hood latch adjacent to the inner fender valance).

4. Unwrap and save the foam anti-rattle pad fitted around the connector assembly.

5. Disconnect the connector.





6. Working on the harness that runs towards the heated windshield, measure 170 mm from the rear face of the connector. Cut away and remove the outer sleeving, which encloses two wires, to this point (A, Illustration 1).

A Measurement from rear of connector for removal of sleeving 170 mm

B Measurement from rear of connector to point for cutting wires 140 mm

C Solder block area of harness

D Heat-shrink sleeve 418 - 104

E Crimp connector 418 - 108.

7. Measure 140 mm from the rear face of the connector and cut both wires at this point (B, Illustration 1). Discard the connector.

8. Strip 6 mm of insulation from each wire.

9. Identify and select the replacement harness having insulation colors corresponding to the existing wiring:

Left side Wire colors are: Black, Green with Slate Right side Wire colors are: Black, Green with Pink.

10. Slide a heat-shrink sleeve 418-004 (from the Jaguar Wiring Harness Repair Kit) on to each wire of the replacement harness (D, Illustration 1). Remove 6 mm of insulation from each wire and crimp in place a crimp connector 418-008 (blue) from the same kit (E, Illustration 1).

11. Align the assembly to the pre-prepared cables on the vehicle and verify that the colors match, then crimp the connectors to the vehicle wiring.

12. Center the heat-shrink sleeves over the crimp connectors and use a hot-air gun to shrink the sleeves in place.

13. Reconnect the replacement connector to the vehicle harness. Rewrap the foam anti-rattle pad around the connector assembly.

14. Restore the connector and cable to its original location, ensuring that the section with the repair is located, as far as possible, out of sight.

15. Reinstall the bulkhead cover.

16. Repeat operations 3-15 above on the opposite side of the vehicle.

17. Remove the fender covers and close the hood. Reconnect the battery and reset the clock.





Parts Information

Order replacement heat shrink sleeves and crimp connectors from Kent Moore at 1-800-345-2233, fax 1-800-578-7375





Warranty Information