wire repair chapter 4. troubleshooting steps l confirm the complaint l study the electrical...
TRANSCRIPT
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!