WIRE REPAIR

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WIRE REPAIR
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TROUBLESHOOTING STEPS

• Confirm the Complaint
• Study the electrical schematic
• Locate and repair the fault
• Test the repair

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TYPES OF WIRE

• Primary Wire
• polyvinyl cross-linked polyethylene

• Battery Cable

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TYPES OF WIRE

• Spark plug wire also known as secondary wire

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WIRE REPAIR

• Type of Repair required
• Ease of Access
• Type of conductor
• Size of wire
• Circuit requirements
• Manufacturer's recommendations

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WIRE SIZE
Less resistance in stranded wire
Larger gauge number means smaller wire
Copper wire is flexible and inexpensive
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AWG to METRIC Wire Sizes
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WIRE MARKINGS
Use different color wires so it is easier to
trace out the wires.
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HEAT SINK
When soldering electronics use heat sink
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SOLDER JOINT
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W Crimp
W CRIMP
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Wire Strippers

• W Crimp
• Insulated Connector
• Non-insulated Connector

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SOLDER LUG
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FUSIBLE LINK REPAIR
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
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Twisted 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.

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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.

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SHEILDED 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

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SOLDERING OF TERMINAL

• Strip Wire as normal
• Form wire terminal around insulation
• Form wire strands on terminal
• Solder Strands to terminal

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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

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TERMINAL TYPES
Spade
Hook
Wire nut
Ring
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
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CONNECTORS

• TYPES
• MOLDED
• MUTIPLE WIRE
• BULKHEAD
• WEATHER-PACK
• METRI-PACK
• ALL USE SOME TYPE OF TERMINAL LOCK

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CONNECTORS
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TERMINAL TOOLS

• Bullet Style
• Spade Style
• Must use to unlock terminal locks
• Use push-to-seat and pull-to-seat

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Whats the difference Weather packs/ Metri Paks

• The Weather Pack system uses only round pin
  terminals or round socket terminals.
• It is used to connect wires together.

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Whats the difference 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.

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Weather packs

• Must use terminal tools
• Use push-to-seat

3-Way Tower and 3-Way Shroud
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Weather packs

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

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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
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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

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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
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Whats What (Proper Names)

• A. Female Connector Assembly
• B. TPA Lock
• C. Male Connector Assembly

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Pull-to-seat" (abbreviated P2S)
 


 


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

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TYPICAL PRINTED CIRCUIT BOARD
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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.

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Thanks to these companies

• Thanks to metripack.com
• http//www.metripack.com/metripackhome.html
• And weatherpack.com
• http//www.weatherpack.com/weatherpackhome.html
• For use of pictures and information on there web
  site.

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Thats All folks!