WIRE REPAIRWIRE REPAIR

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

WIRE SIZEWIRE SIZE

Less resistance instranded wire

Larger gauge number means smaller wire

Copper wire isflexible and inexpensive

AWG to METRIC Wire SizesAWG to METRIC Wire Sizes

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

W W CrimpCrimp

“W”CRIMP

Wire StrippersWire Strippers

W Crimp Insulated Connector Non-insulated Connector

SOLDER LUGSOLDER LUG

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

Twisted Pair WireTwisted Pair Wire

A Twisted Pair Wire is a wire that is just twisted. Since both wires have nearly equal exposure to

any interference, the differential noise is slight.

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

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

CONNECTORSCONNECTORS

TERMINAL TOOLSTERMINAL TOOLS

Bullet Style Spade Style Must use to

unlock terminal locks

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

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

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 Paks Weather packs/ Metri Paks

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

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

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.

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/metripackhome.html

And weatherpack.com http://www.weatherpack.com/weatherp

ackhome.htmlFor use of pictures and information on

there web site.

That’s All folks!That’s All folks!