WIRE REPAIR Chapter 4

TROUBLESHOOTING STEPS Confirm the Complaint Study the electrical schematic Locate and repair the fault Test the repair

TYPES OF WIRE Primary Wire polyvinyl & cross-linked polyethylene Battery Cable

TYPES OF WIRE Spark plug wire also known as secondary wire

WIRE REPAIR Pg L84 Type of Repair required Ease of Access Type of conductor Size of wire Circuit requirements Manufacturer's recommendations

WIRE SIZE Less resistance in stranded wire Larger gauge number means Page C85-87 Less resistance in stranded wire Larger gauge number means smaller wire Copper wire is flexible and inexpensive

AWG to METRIC Wire Sizes Page C87

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

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

HEAT SINK When soldering electronics use heat sink

Page L91 SOLDER JOINT

W Crimp “W” CRIMP Page L87

Wire Strippers W Crimp Insulated Connector Non-insulated Connector

Page L90 SOLDER LUG

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

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.

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.

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.

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

SOLDERING OF TERMINAL Strip Wire as normal Form wire terminal around insulation Form wire strands on terminal Solder Strands to terminal

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

TERMINAL TYPES Wire nut Spade Hook Ring T-Tap Male bullet 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

CONNECTORS Page C88 & L98 TYPES ALL USE SOME TYPE OF TERMINAL LOCK MOLDED MUTIPLE WIRE BULKHEAD WEATHER-PACK METRI-PACK ALL USE SOME TYPE OF TERMINAL LOCK Page C88 & L98

CONNECTORS

TERMINAL TOOLS Page C89 & L97 Bullet Style Spade Style Must use to unlock terminal locks Use push-to-seat and pull-to-seat

What’s 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.

What’s 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.

Weather packs Must use terminal tools Use push-to-seat 3-Way Tower and 3-Way Shroud

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

Weather packs Weather Pack Tower, Weather Pack Shroud                                                                                              

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

How to repair Weather packs First choose the right Terminal Extractor remover or Pick For the job.

How to repair Weather packs Push in the tool to release the tangs of the Terminal.

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.

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

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

What’s What (Proper Names) A. Female Connector Assembly B. TPA Lock C. Male Connector Assembly

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

Common Two-Wire Sensor Connector Plug Fuel Injector Connector Common Three-Wire Sensor Connector Common Two-Wire Sensor Connector

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.

TYPICAL PRINTED CIRCUIT BOARD

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.

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.

That’s All folks!