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 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

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

9. 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. Page L91
SOLDER JOINT

12. W Crimp
“W”
CRIMP
Page L87

13. Wire Strippers
W Crimp
Insulated Connector
Non-insulated Connector

14. Page L90
SOLDER LUG

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.

18. 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

20. 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 gauge
Blue gauge
Yellow 10-12gauge
Quality

22. 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

23. 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

24. 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

26. 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.

27. 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.

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

29. 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
                               
                              
                              

31. 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

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

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

34. 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 gauge
Purple is 20 gauge
Red is 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. What’s What (Proper Names)
A. Female Connector Assembly
B. TPA Lock
C. Male Connector Assembly

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

39. 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
And weatherpack.com
For use of pictures and information on there web site.

44. That’s All folks!