WIRE REPAIR

1
WIRE REPAIR

• Chapter 4

2
TROUBLESHOOTING STEPS

• Confirm the Complaint
• Study the electrical schematic
• Locate and repair the fault
• Test the repair

3
TYPES OF WIRE

• Primary Wire
• polyvinyl cross-linked polyethylene

• Battery Cable

4
TYPES OF WIRE

• Spark plug wire also known as secondary wire

5
WIRE REPAIR
Pg L84

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

6
WIRE SIZE
Page C85-87
Less resistance in stranded wire
Larger gauge number means smaller wire
Copper wire is flexible and inexpensive
7
AWG to METRIC Wire Sizes
Page C87
8
Wire 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
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WIRE MARKINGS
Use different color wires so it is easier to
trace out the wires.
10
HEAT SINK
When soldering electronics use heat sink
11
SOLDER JOINT
Page L91
12
W Crimp
W CRIMP
Page L87
13
Wire Strippers

• W Crimp
• Insulated Connector
• Non-insulated Connector

14
SOLDER LUG
Page L90
15
FUSIBLE LINK REPAIR
Page L93
1. Remove damaged fusible link 2. Prepare
cut wire end for new fusible link 3.
Install crimp style lug 4. Install new fusible
link by crimping link to lug 5. Solder link
to lug also 6. Apply Heat Shrink to
connection
16
Twisted 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.

17
Twisted 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.

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HEAT 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.

19
SHEILDED CABLE REPAIR
Page L93

• Cut out damaged section of wire
• Remove 1 inch out outer insulation
• Unwrap Mylar tape
• Splice Cut wires
• Wrap Mylar tape
• Splice Drain Wire

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SOLDERING OF TERMINAL

• Strip Wire as normal
• Form wire terminal around insulation
• Form wire strands on terminal
• Solder Strands to terminal

21
TERMINAL 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

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TERMINAL TYPES
Spade
Hook
Wire nut
Ring
Quick Splice
T-Tap
Male bullet
Female bullet
Butt connector
Female quick Connect
Male quick connect
Self-Stripping fuse holder
Closed End Connector
Fully Insulated Female Quick connect
Non insulated Butt Connector
Non Insulated ring
Fuse tap
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CONNECTORS

• TYPES
• MOLDED
• MUTIPLE WIRE
• BULKHEAD
• WEATHER-PACK
• METRI-PACK
• ALL USE SOME TYPE OF TERMINAL LOCK

Page C88 L98
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CONNECTORS
25
TERMINAL TOOLS
Page C89 L97

• Bullet Style
• Spade Style
• Must use to unlock terminal locks
• Use push-to-seat and pull-to-seat

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Whats the difference Weather packs/ Metri Packs

• The Weather Pack system uses only round pin
  terminals or round socket terminals.
• It is used to connect wires together.

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Whats the difference 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.

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Weather packs

• Must use terminal tools
• Use push-to-seat

3-Way Tower and 3-Way Shroud
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Weather packs

• Tower and Shroud
• Can have 1 to 6 connectors
• Can be flat
• Square
• Or round

30
Weather packs

• Weather Pack Tower, Weather Pack Shroud

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How to repair Weather packs
Seal loaded on stripped wire(wire stripped 5.0mm
or 3/16")
Terminal, seal and wire(positioned to be
crimped)
Crimped Weather Pack Terminal
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How to repair Weather packs
First choose the right Terminal Extractor
remover or Pick For the job.
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How to repair Weather packs
Push in the tool to release the tangs of the
Terminal.
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How to repair Weather packs
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.
35
Cable seals What size, why so many colors

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

36
Metri Paks

• Must use terminal tools
• Use push-to-seat and pull- to-seat

Sealed Metri-Pack 280 Series One-Way Housings and
Locks
Sealed Metri-Pack 150 Series Two-Way Housings and
Locks
37
Whats What (Proper Names)

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

38
Pull-to-seat" (abbreviated P2S)
 


 


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Common Two-Wire Sensor Connector Plug
Fuel Injector Connector
Common Three-Wire Sensor Connector
Common Two-Wire Sensor Connector
40
PRINTED CIRCUIT BOARDS
Page C91

• 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.

41
TYPICAL PRINTED CIRCUIT BOARD
42
Removing 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.

43
Thanks to these companies

• 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.

44
Thats All folks!