WIRE REPAIR Chapter 4. TROUBLESHOOTING STEPS l Confirm the Complaint l Study the electrical schematic l Locate and repair the fault l Test the repair.

WIRE REPAIRWIRE REPAIR

Chapter 4

TROUBLESHOOTING TROUBLESHOOTING STEPSSTEPS Confirm the ComplaintStudy the electrical schematic

Locate and repair the faultTest the repair

TYPES OF WIRE TYPES OF WIRE

Battery Cable

Primary Wire polyvinyl &

cross-linked polyethylene

TYPES OF WIRE TYPES OF WIRE

Spark plug wire also known as secondary wire

WIRE REPAIRWIRE REPAIR

Type of Repair required Ease of Access Type of conductor Size of wire Circuit requirements Manufacturer's recommendations

Pg L84

WIRE SIZEWIRE SIZEPage C85-87

Less resistance instranded wire

Larger gauge number means smaller wire

Copper wire isflexible and inexpensive

AWG to METRIC Wire SizesAWG to METRIC Wire SizesPage C87

Wire Color AbbreviationsWire Color Abbreviations

WHT White

YEL Yellow

BLK Black

BLU Blue

GRN Green

RED Red

ORN Orange

PNK Pink

BRN Brown

GRY Gray

PUR Purple

LT BLU Light Blue

LT GRN Light Green

WIRE MARKINGSWIRE MARKINGS

Use different color wires so it is easier to trace out the wires.

HEAT SINKHEAT SINK

When solderingelectronics use heatsink

SOLDER JOINTSOLDER JOINT Page L91

W W CrimpCrimp

“W”CRIMP

Page L87

Wire StrippersWire Strippers

W Crimp Insulated Connector Non-insulated Connector

SOLDER LUGSOLDER LUGPage L90

FUSIBLE LINK REPAIRFUSIBLE LINK REPAIR

1. Remove damaged fusible link2. Prepare cut wire end for new fusible link 3. Install crimp style lug4. Install new fusible link by crimping link to lug5. Solder link to lug also6. Apply Heat Shrink to connection

Page L93

Twisted Pair WireTwisted Pair Wire

A Twisted Pair Wire is two wires that are twisted together.

Since both wires have nearly equal exposure to any interference, the differential noise is slight.

Twisted Pair Wire RepairTwisted Pair Wire Repair Never use a bypass wire to test the wire. Resistance of the two wires should be

identical. Use the same gauge and Length of wire. Maintain the twist rate. Same routing. Crimp and Seal with a good approved

connectors.

HEAT SHRINKHEAT SHRINK Cut Wire Insulation

and Strip off Install Crimp

terminal Prepare Heat

Shrink Install Heat Shrink Apply heat to Heat

Shrink tube Heat gun works best.

SHEILDED CABLE REPAIRSHEILDED CABLE REPAIR

Cut out damaged section of wire

Remove 1 inch out outer insulation

Unwrap Mylar tape Splice Cut wires Wrap Mylar tape Splice Drain Wire

Page L93

SOLDERING OF TERMINALSOLDERING OF TERMINAL

Strip Wire as normal

Form wire terminal around insulation

Form wire strands on terminal

Solder Strands to terminal

TERMINAL TYPESTERMINAL TYPES

Crimp Style Non-crimp Style/Solder

– No insulation Different wire gauge sizes. Color codes

– Red 18-22 gauge – Blue 14-16 gauge – Yellow 10-12gauge

Quality

TERMINAL TYPESTERMINAL TYPESRing Spade Hook

Male bullet

Female quickConnect

Male quickconnect

Female bullet

Wire nut

Non insulatedButt Connector

Fully InsulatedFemaleQuick connect

T-TapButt connector

NonInsulatedring

Fuse tap

Self-Stripping fuse holder

Closed End Connector

QuickSplice

CONNECTORSCONNECTORS TYPES

– MOLDED– MUTIPLE WIRE– BULKHEAD– WEATHER-PACK– METRI-PACK

ALL USE SOME TYPE OF TERMINAL LOCK

Page C88 & L98

CONNECTORSCONNECTORS

TERMINAL TOOLSTERMINAL TOOLS

Bullet Style Spade Style Must use to

unlock terminal locks

Use push-to-seat and pull-to-seat

Page C89 & L97

What’s the differenceWhat’s the difference Weather packs/ Metri Packs Weather packs/ Metri Packs

The Weather Pack system uses only round pin terminals or round socket terminals.

It is used to connect wires together.

What’s the differenceWhat’s the difference Weather packs/ Metri Packs Weather packs/ Metri Packs

Metri-Pack are the other connectors, male blade Metri-Pack is more likely to connect to a device

such as a sensor, a switch, a relay, a header block, or even an electronic control module. There are only a few in-line “mating” Metri-Pack parts.

Weather packsWeather packs

Must use terminal tools Use push-to-seat

3-Way Tower and 3-Way Shroud

Weather packsWeather packsTower and Shroud Can have 1 to 6 connectors Can be flat Square Or round

Weather packsWeather packsWeather Pack Tower, Weather Pack Shroud

How to repair Weather How to repair Weather packspacks

Seal loaded on stripped wire(wire stripped 5.0mm or 3/16")

Terminal, seal and wire(positioned to be crimped) Crimped Weather Pack Terminal

How to repair Weather How to repair Weather packspacks

First choose the right Terminal Extractor remover or PickFor the job.

How to repair Weather How to repair Weather packspacks

Push in the tool to release the tangs of the Terminal.

How to repair Weather How to repair Weather packspacks

Before you put it back together make sure that the tangs are out so it will stay in place.Do not bend out to far or they will brake off.

Cable seals; What size, why so Cable seals; What size, why so many colorsmany colors

Blue is 12 gauge Gray is 14 gauge Green is 18-20 gauge Purple is 20 gauge Red is 16-20 gauge

Metri PaksMetri Paks

Must use terminal tools

Use push-to-seat and pull- to-seat

Sealed Metri-Pack 150 Series Two-Way Housings and Locks

Sealed Metri-Pack 280 Series One-Way Housings and Locks

What’s What (Proper What’s What (Proper Names)Names)

A. Female Connector Assembly B. TPA Lock C. Male Connector Assembly

Pull-to-seat" (abbreviated Pull-to-seat" (abbreviated P2S) P2S)

Common Three-Wire Sensor Connector Common Two-Wire Sensor Connector

Fuel Injector Connector Common Two-Wire Sensor Connector Plug

PRINTED CIRCUIT BOARDSPRINTED CIRCUIT BOARDS

Used on Instrument Panels Made of thin phenolic or fiberglass

board Conductive metal is etched to

make circuits. Must use care when servicing

printed circuit board. Tears, oil off fingers, etc.

Page C91

TYPICAL PRINTED CIRCUIT TYPICAL PRINTED CIRCUIT BOARDBOARD

Removing electrical tapeRemoving electrical tape

One little trick to removing electrical tape is to use a seam ripper.

Do not force, a steady easy push will allow it to cut the tape.

Thanks to these Thanks to these companiescompanies Thanks to metripack.com

http://www.metripack.com

And weatherpack.com http://www.weatherpack.com For use of pictures and information on

there web site.

That’s All folks!That’s All folks!