Discovery I (LJ) V8-3.9L (1994)
The plier crimp size is determined by the wire size and insulation diameter.
larger wire terminals may have to be crimped with slip joint pliers and soldered
Strip approximately 3 mm (1/8 inch) of insulation
Insert the appropriate terminal into the special crimping pliers partially close plier to hold terminal
Insert stripped wire into terminal and firmly close plier
Repeat procedure for insulation crimp
Test crimp by applying a pull of 30 Newtons (approx. 7.0 lbs.)
HEAT SHRINKABLE TUBING
The use of heat shrinkable tubing insulation on terminals and wiring repair is recommended. This will ensure that the repair will be properly insulated
and will match the factory wiring.
The correct diameter heat shrinkable tubing is cut to length and installed over the terminal and wire. The length of the tubing should be long enough to
insulate the terminal and extend over the wire insulation approximately 12.5 mm (1/2 inch). The tubing should then be shrunk to a tight fit using a heat
gun as shown. Care should be taken not to overheat or burn this shrink tubing.
Heat shrinkable tubing is available locally in various lengths and diameters.
The following five-step troubleshooting procedure is recommended.
1. Verify the Problem
Check the operation of the circuit to be sure you understand the problem. Do not begin disassembly or testing until you have narrowed down the
2. Analyze the Circuit Diagram (schematic)
Analyze the diagram. Check circuits that share the wiring with the problem circuit. The names of shared circuits are often given on each Circuit
Diagram to aid troubleshooting. Shared power and ground circuits can be found in the Power and Ground Distribution. Try to operate the shared
circuits. If these circuits work, then the shared wiring is OK. The cause must be within the wiring used only by the problem circuit. If several
circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty.
3. Find the Cause
Narrow down the possible causes.
Before you replace a component, check power, signal and ground wires at the component harness connector.