1. WIRE REPAIR

2. TROUBLESHOOTING STEPS l Confirm the Complaint l Study the electrical schematic l Locate and repair the fault l Test the repair

3. TYPES OF WIRE l Battery Cable l Primary Wire l polyvinyl & cross-linked polyethylene

4. TYPES OF WIRE l Spark plug wire also known as secondary wire

5. WIRE REPAIR l Type of Repair required l Ease of Access l Type of conductor l Size of wire l Circuit requirements l Manufacturer's recommendations

6. WIRE SIZE Less resistance in stranded wire Larger gauge number means smaller wire Copper wire is flexible and inexpensive

7. AWG to METRIC Wire Sizes

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

9. HEAT SINK When soldering electronics use heat sink

10. SOLDER JOINT

11. W Crimp “W” CRIMP

12. Wire Strippers l W Crimp l Insulated Connector l Non-insulated Connector

13. SOLDER LUG

14. 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

15. Twisted Pair Wire l A Twisted Pair Wire is a wire that is just twisted. l Since both wires have nearly equal exposure to any interference, the differential noise is slight.

16. HEAT SHRINK l Cut Wire Insulation and Strip off l Install Crimp terminal l Prepare Heat Shrink l Install Heat Shrink l Apply heat to Heat Shrink tube Heat gun works best.

17. SHEILDED CABLE REPAIR l Cut out damaged section of wire l Remove 1 inch out outer insulation l Unwrap Mylar tape l Splice Cut wires l Wrap Mylar tape l Splice Drain Wire

18. SOLDERING OF TERMINAL l Strip Wire as normal l Form wire terminal around insulation l Form wire strands on terminal l Solder Strands to terminal

19. TERMINAL TYPES l Crimp Style l Non-crimp Style/Solder –No insulation l Different wire gauge sizes. l Color codes –Red 18-22 gauge –Blue 14-16 gauge –Yellow 10-12gauge l Quality

20. TERMINAL TYPES Ring SpadeHook Male bullet Female quick Connect Male quick connect Female bullet Wire nut Non insulated Butt Connector Fully Insulated Female Quick connect T-Tap Butt connector Non Insulated ring Fuse tap Self- Stripping fuse holder Closed End Connector Quick Splice

21. CONNECTORS l TYPES – MOLDED – MUTIPLE WIRE – BULKHEAD – WEATHER-PACK – METRI-PACK l ALL USE SOME TYPE OF TERMINAL LOCK

22. CONNECTORS

23. TERMINAL TOOLS l Bullet Style l Spade Style l Must use to unlock terminal locks l Use push-to-seat and pull-to-seat

24. What’s the difference Weather packs/ Metri Paks l The Weather Pack system uses only round pin terminals or round socket terminals. l It is used to connect wires together.

25. What’s the difference Weather packs/ Metri Paks l Metri-Pack are the other connectors, male blade l 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.

26. Weather packs l Must use terminal tools l Use push-to-seat 3-Way Tower and 3-Way Shroud

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

28. 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

29. Cable seals; What size, why so many colors l Blue is 12 gauge l Gray is 14 gauge l Green is 18-20 gauge l Purple is 20 gauge l Red is 16-20 gauge

30. Metri Paks Metri Paks l Must use terminal tools l 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

31. What’s What (Proper Names) l A. Female Connector Assembly l B. TPA Lock l C. Male Connector Assembly

32. Pull-to-seat" (abbreviated P2S)

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

34. PRINTED CIRCUIT BOARDS l Used on Instrument Panels l Made of thin phenolic or fiberglass board l Conductive metal is etched to make circuits. l Must use care when servicing printed circuit board. Tears, oil off fingers, etc.

35. TYPICAL PRINTED CIRCUIT BOARD

36. Removing electrical tape l One little trick to removing electrical tape is to use a seam ripper. l Do not force, a steady easy push will allow it to cut the tape.

37. Thanks to these companies l Thanks to metripack.com l http://www.metripack.com/metripackhom e.html http://www.metripack.com/metripackhom e.html l And weatherpack.com l http://www.weatherpack.com/weatherpac khome.html http://www.weatherpack.com/weatherpac khome.html For use of pictures and information on there web site.

38. That’s All folks!