WIRE REPAIR

TROUBLESHOOTING
STEPS
Confirm the Complaint
Study the electrical
schematic
Locate and repair the fault
Test the repair
 TYPES OF WIRE

 Primary Wire
 Battery Cable  polyvinyl &
cross-linked
polyethylene
 TYPES OF WIRE

 Spark plug wire also known as secondary wire

WIRE REPAIR

 Type of Repair required

 Ease of Access
 Type of conductor
 Size of wire
 Circuit requirements
 Manufacturer's recommendations
 WIRE SIZE

Less resistance in
stranded wire
Larger gauge
number means
smaller wire
Copper wire is
flexible and
inexpensive
AWG to METRIC Wire Sizes
WIRE MARKINGS

Use different color wires so it is easier to trace out the wires.

HEAT SINK

When soldering
electronics use heat
sink
SOLDER JOINT
 W
Crimp
“W”
CRIMP
Wire Strippers

 W Crimp
 Insulated Connector
 Non-insulated Connector
SOLDER LUG
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
 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.
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.
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
SOLDERING OF TERMINAL

 Strip Wire as normal

 Form wire terminal
around insulation
 Form wire strands
on terminal
 Solder Strands to
terminal
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
 Wire nut Spade Hook
Ring
TERMINAL TYPES
Quick
T-Tap Splice
Male bullet Female bullet
Butt connector

Female quick Male quick

Self- Connect connect
Stripping Closed
fuse Fully Insulated
holder End Non insulated
Female
Connector Quick connect Butt Connector
Non
Insulated
ring

Fuse tap
CONNECTORS
 TYPES
– MOLDED
– MUTIPLE WIRE
– BULKHEAD
– WEATHER-PACK
– METRI-PACK
 ALL USE SOME TYPE
OF TERMINAL LOCK
CONNECTORS
TERMINAL TOOLS

 Bullet Style
 Spade Style
 Must use to unlock
terminal locks
 Use push-to-seat
and pull-to-seat
 What’s 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.
 What’s 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.
 Weather packs
 Must use terminal tools
 Use push-to-seat

3-Way Tower and 3-Way Shroud

 Weather packs
Tower and Shroud
 Can have 1 to 6 connectors
 Can be flat
 Square
 Or round
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
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
 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

What’s What (Proper Names)

 A. Female Connector Assembly

 B. TPA Lock
 C. Male Connector Assembly
Pull-to-seat" (abbreviated P2S)
Common Two-Wire Sensor Connector Plug
Fuel Injector Connector

Common Two-Wire Sensor Connector Common Three-Wire Sensor Connector

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.
TYPICAL PRINTED CIRCUIT
BOARD
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.
 Thanks to these companies
 Thanks to metripack.com
 http://www.metripack.com/metripackhom
e.html

 And weatherpack.com
 http://www.weatherpack.com/weatherpac
khome.html
For use of pictures and information on there
web site.
That’s All folks!