Wiring and wire repairs

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Wiring and wire repairs

• Wire sizes
• Conductor ratings
• Circuit protection
• Connectors and terminals
• Wire repairs

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Wire sizes

• AWG American Wire Gauge system
• As gauge number increases, wire diameter
  decreases
  
• As diameter decreases, current carrying
  capabilities also decrease
  
• As gauge number decreases, wire diameter
  increases as does current carrying capabilities

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• Battery cables are the largest wires on the
  car
  
• because they carry the greatest amperage

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Wire lengths vs. diameter
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Conductor ratings
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Circuit protection

• Fuses
• Mini
• Blade type fuses (ATO)
• maxi
• Rated and colored according to amperage capacity

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Circuit protection

• Circuit breakers
• Uses bimetallic contacts that deform when
  overheated and open circuit preventing circuit
  overload
  
• Breakers are usually cycling type for automatic
  resets
  

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Blade type breakers can replace blade type fuses
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Circuit protection

• Circuit breakers often control critical circuits
  or circuits that may incur power surges that
  would normally burn a fuse
  
• Headlights
• Power windows
• Power seats

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Circuit protection

• Fusible links
• Short length of wire usually 4 wire numbers
  smaller than the wire it protects
  
• Covered in nonflammable insulation that will not
  separate if the wire inside burns open

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Connectors and terminals

• A connector is a plastic component that
  connects two harnesses
  
• A terminal is a metal fastener used to
  terminate the end of the wire
  
• Terminals usually snap into a connector and
  connect to other terminals
  

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Wire repair

• Soldering use rosin core solder for wiring
  repairs
  
• Crimp-on connectors
• Both crimp-on and soldered joints should be
  sealed with shrink tubing
  
• Aftermarket connectors available that require use
  of heat gun only

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