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[object Object],[object Object],[object Object],[object Object],OBJECTIVES: After studying Chapter 35, the reader should be able to:
[object Object],[object Object],[object Object],[object Object],[object Object],KEY TERMS: Continued
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],KEY TERMS:
AUTOMOTIVE WIRING ,[object Object],See this chart on Page 360 of your textbook.   Copper is the best electrical conductor besides silver, which is far more expensive.  Continued
[object Object],14-gauge wire is smaller than 10-gauge wire. The  greater the amount of current (amps), the  larger  the conducting wire (smaller gauge number) required.  Continued This chart that compares the AWG number to the actual wire diameter in inches. See this chart on Page 360 of your textbook.
[object Object],NOTE:   Always check the installation instructions or the manufacturer’s specifications for wire gauge size before replacing any automotive wiring. 20–22 gauge : radio speaker wires 18 gauge : small bulbs and short leads 16 gauge : taillights, gas gauge, turn signals, windshield wipers 14 gauge : horn, radio power lead, headlights, lighter, brake lights 12 gauge : headlight switch-to-fuse box, rear window defogger, power windows and locks 10 gauge : ammeter, generator, or alternator-to-battery Continued
[object Object],See this chart on Page 361 of your textbook.   Notice the metric wire size increases with size (area), where the AWG gauge size gets smaller with larger-size wire. Continued
[object Object],See this chart on Page 361 of your textbook.   Continued A trailer may require 14-gauge wire to light all the trailer lights, but if the wire required is over 25 feet long, 12-gauge wire should be used. Automotive wire, except spark plug wire, is often called  primary wire  as it is designed to operate at or near battery voltage.
Yes. The American wire gauge (AWG) sizing of wire includes all gauge numbers, even though the most commonly used sizes are even numbered, such as 12, 14, or 16. Because the sizes are so close, wire in every size is not commonly stocked, but it can be ordered for a higher price. Therefore, if a larger wire size is needed, it is common practice to select the next lower, even-numbered gauge. See the chart following for a comparison of the wire sizes. Do they make 13-Gauge Wire? See the complete AWG chart on Page 362 of your textbook.
[object Object],0000 000 00 0 1 2 3 4 5 6 7 8 9 10 11 12 13 0.46 0.4096 0.3648 0.3249 0.2893 0.2576 0.2294 0.2043 0.1819 0.162 0.1443 0.1285 0.1144 0.1019 0.0907 0.0808 0.072 Diameter (inches) This is a partial chart. See the complete AWG chart on Page 362 of your textbook.   Do they make 13-Gauge Wire? YES!
BRAIDED GROUND STRAPS ,[object Object],Continued
Figure 35–1  All lights and accessories ground to the body of the vehicle. Body ground wires such as this one are needed to conduct all of the current from these components back to the negative terminal of the battery. The body ground wire connects the body to the engine. Most battery negative cables attach to the engine.
The  skin effect  is the term used to describe how high-frequency AC electricity flows through a conductor. Direct current flows through a conductor, but alternating current tends to travel through the outside (skin) of the conductor. Because of the skin effect, most audio (speaker) cable is constructed of very small-diameter copper wires instead of fewer larger strands, because the smaller wire has a greater surface area and therefore results in less resistance to the flow of AC voltage. What is the Skin Effect? NOTE:   Body ground wires are necessary to provide a circuit path for the lights and accessories that ground to the body and flow to the negative battery terminal. Continued
A  twisted pair  is used to transmit low-voltage signals using two wires that are twisted together. Electromagnetic interference can create a voltage in a wire, and twisting the two signal wires cancels out the induced voltage. A twisted pair means that the two wires have at least 9 twists (turns) per foot (13 twists per meter). What is a Twisted Pair?
BATTERY CABLES ,[object Object],Continued
Figure 35–2 Battery cables are designed to carry heavy starter current and are therefore usually 4-gauge or larger wire. Note that this battery is covered with a thermal blanket covering to help protect the battery from high under-hood temperatures. The wiring is also covered with plastic conduit also called split-loom tubing.
JUMPER CABLES ,[object Object]
FUSES AND CIRCUIT PROTECTION DEVICES ,[object Object],[object Object],Continued
[object Object],[object Object],NOTE:   The SAE term for a cigarette lighter is  cigar lighter  because the diameter of the heating element is large enough for a cigar. The term  cigarette lighter  will be used in this book because it is common usage. Continued
Figure 35–3  This figure shows a typical automotive fuse panel.
[object Object],Figure 35–4 Blade-type fuses can be tested through openings in the plastic at the top of the fuse. See the chart on Page 363 of your textbook.
[object Object],Continued This also makes troubleshooting much easier, because each circuit is separate. See the chart on Page 363 of your textbook.   The amperage rating and fuse color for mini fuses include:
[object Object],Continued See the chart on Page 364 of your textbook.   The amperage rating and corresponding color for maxi fuses are shown here:
[object Object],Figure 35–6 A comparison of the various types of protective devices used in most vehicles. Continued
[object Object],Continued
Figure 35–7  To test a fuse, use a test light to check for power at the power side of the fuse. The ignition switch and lights may have to be on before some fuses receive power. If the fuse is good, the test light should light on both sides (power side and load side) of the fuse. ,[object Object],A test light should light on both sides. If the test light only lights on one side, the fuse is blown or open. If the test light does not light on either side of the fuse, then that circuit is not being supplied power.  Use an ohmmeter to test  fusible link cartridges .
[object Object],Continued
Figure 35–8 Typical blade circuit breaker fits into the same space as a blade fuse. If excessive current flows through the bimetallic strip, the strip bends and opens the contacts and stops current flow. When the circuit breaker cools, the contacts close again, completing the electrical circuit. Continued
[object Object],Figure 35–9 These electrical symbols are used to represent circuit breakers. Continued
[object Object],Continued
Figure 35–10 (a) Normal operation of a PTC circuit protector in a power window motor circuit. Note the many conducting paths. With normal current flow, the temperature of the PTC circuit protector remains normal. (b) When current exceeds the amperage rating of the PTC circuit protector, the polymer material that makes up the electronic circuit protector increases in resistance. As shown here, a high-resistance electrical path still exists even though the motor will stop operating as a result of the very low current flow through the very high resistance. The circuit protector will not reset or cool down until voltage is removed from the circuit. ,[object Object],(a) (b) When the circuit is back on, the component may operate normally for a short time; however, the PTC resistance again increases to limit current flow.  Continued
Figure 35–11  PTC circuit protectors are used extensively in the power distribution center of this Chrysler vehicle. Continued
[object Object],Figure 35–12  Fusible links are usually located close to the battery and are usually attached to a junction block. Notice that they are only 6 to 9 inches long and feed more than one fuse from each fusible link. Special thick insulation over the wire may make it look larger than other wires of the same gauge number.  Continued
[object Object],Continued
[object Object],Continued
Corroded connections are a major cause of intermittent electrical problems and open circuits. The usual sequence of conditions is as follows: Look for the “Green Crud” ,[object Object],[object Object],The solution is that if corroded connectors are noticed, the terminal should be cleaned and the condition of the electrical connection to the wire terminal end(s) confirmed. Many automobile manufacturers recommend using a dielectric silicone or lithium-based grease inside connectors to prevent moisture from getting into and attacking the connector.
TERMINALS AND CONNECTORS ,[object Object],Continued
Figure 35–13  Some terminals have seals attached to help seal the electrical connections. Continued
[object Object],Figure 35–14 Separate a connector by opening the lock and pulling the two apart. Continued ,[object Object],[object Object],Figure 35–15  The secondary locks help retain the terminals in the connector. ,[object Object]
Figure 35–16 Use a small removal tool, sometimes called a pick, to release terminals from the connector. ,[object Object]
WIRE REPAIR ,[object Object],Continued Figure 35–17 Always use rosin-core solder for electrical or electronic soldering. Also, use small-diameter solder for small soldering irons. Use large-diameter solder only for large-diameter (large-gauge) wire and higher-wattage soldering irons (guns). Solder   An alloy of tin and lead,  solder  makes a good electrical contact between two wires or connections in an electrical circuit. A flux must be used to help clean the area and to help make the solder flow. Solder made with resin (rosin) contained in the center, is called  rosin-core solder .
[object Object],[object Object],[object Object],[object Object],NOTE:   The melting points stated here can vary depending on the purity of the metals used.
[object Object],Figure 35–18  A butane soldering tool. The cap has a built-in striker to light a converter in the tip of the tool. This handy soldering tool produces the equivalent of 60 watts of heat. It operates for about 1/2 hour on one charge from a commonly available butane refill dispenser. Soldering a wiring splice includes the following steps: Continued ,[object Object]
[object Object],[object Object],[object Object],The solder should have a shiny appearance. Dull-looking solder may be caused by not reaching a high enough temperature, which results in a  cold solder joint . Reheating the splice and allowing it to cool often restores the shiny appearance. An acid-core solder is also available but should  only  be used for soldering sheet metal.  Continued
[object Object],Figure 35–19 Notice that to create a good crimp the open part of the terminal is placed in the jaws of the crimping tool toward the anvil or the W-shape part. Continued
Figure 35–20  All hand-crimped splices or terminals should be soldered to be assured of a good electrical connection. ,[object Object]
[object Object],Continued
Figure 35–21  A butane torch especially designed for use on heat shrink applies heat without an open flame, which could cause damage. Continued
[object Object],Figure 35–22  A typical crimp-and-seal connector. This type of connector is first lightly crimped to retain the ends of the wires and then it is heated. The tubing shrinks around the wire splice and a thermoplastic glue melts on the inside to provide an effective weather-resistant seal. Continued
[object Object],Figure 35–23  Heating the crimp-and-seal connector melts the glue and forms an effective seal against moisture. Step #1   Strip insulation from the ends of the wire (about 5/16 inch, or 8 mm). Step #2  Select proper size crimp-and-seal connector for the gauge of wire being repaired. Insert wires into the splice sleeve and crimp. Step #3 Apply heat to the connector until the sleeve shrinks down around the wire and a small amount of sealant is observed around the ends of the sleeve. Continued
[object Object],Continued
[object Object],Step #1  Carefully strip only about 1/4 inch (6 millimeters) of insulation from the aluminum wire, being careful not to nick or damage the aluminum wire case. Step #2  Use a crimp connector to join two wires together. Do  not  solder an aluminum wire repair. Solder will not readily adhere to aluminum because the heat causes an oxide coating on the surface of the aluminum. Step #3  To prevent corrosion, the spliced, crimped connection must be coated with petroleum jelly. Step #4  The coated connection should be covered with shrinkable plastic tubing or wrapped with electrical tape to seal out moisture.
Most electrical wiring is protected with a plastic convoluted conduit, which comes in many different grades depending on the temperature of the surrounding area. A painted stripe usually indicates that the conduit is designed for high-temperature applications and is used where it would be placed on or near the engine. Do not use inexpensive conduit around wiring that will be exposed to temperatures higher than 200°F (85°C). What Does the Stripe on the Plastic Conduit Mean? Figure 35–24 The color stripe on the side of the convoluted conduit indicates that the conduit is designed for high-temperature applications.
SUMMARY ,[object Object],[object Object],[object Object],[object Object],Continued
SUMMARY ,[object Object],[object Object],( cont. )
end

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Chapter 35

  • 2.
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  • 8.
  • 9.
  • 10. Yes. The American wire gauge (AWG) sizing of wire includes all gauge numbers, even though the most commonly used sizes are even numbered, such as 12, 14, or 16. Because the sizes are so close, wire in every size is not commonly stocked, but it can be ordered for a higher price. Therefore, if a larger wire size is needed, it is common practice to select the next lower, even-numbered gauge. See the chart following for a comparison of the wire sizes. Do they make 13-Gauge Wire? See the complete AWG chart on Page 362 of your textbook.
  • 11.
  • 12.
  • 13. Figure 35–1 All lights and accessories ground to the body of the vehicle. Body ground wires such as this one are needed to conduct all of the current from these components back to the negative terminal of the battery. The body ground wire connects the body to the engine. Most battery negative cables attach to the engine.
  • 14. The skin effect is the term used to describe how high-frequency AC electricity flows through a conductor. Direct current flows through a conductor, but alternating current tends to travel through the outside (skin) of the conductor. Because of the skin effect, most audio (speaker) cable is constructed of very small-diameter copper wires instead of fewer larger strands, because the smaller wire has a greater surface area and therefore results in less resistance to the flow of AC voltage. What is the Skin Effect? NOTE: Body ground wires are necessary to provide a circuit path for the lights and accessories that ground to the body and flow to the negative battery terminal. Continued
  • 15. A twisted pair is used to transmit low-voltage signals using two wires that are twisted together. Electromagnetic interference can create a voltage in a wire, and twisting the two signal wires cancels out the induced voltage. A twisted pair means that the two wires have at least 9 twists (turns) per foot (13 twists per meter). What is a Twisted Pair?
  • 16.
  • 17. Figure 35–2 Battery cables are designed to carry heavy starter current and are therefore usually 4-gauge or larger wire. Note that this battery is covered with a thermal blanket covering to help protect the battery from high under-hood temperatures. The wiring is also covered with plastic conduit also called split-loom tubing.
  • 18.
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  • 21. Figure 35–3 This figure shows a typical automotive fuse panel.
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  • 27.
  • 28.
  • 29. Figure 35–8 Typical blade circuit breaker fits into the same space as a blade fuse. If excessive current flows through the bimetallic strip, the strip bends and opens the contacts and stops current flow. When the circuit breaker cools, the contacts close again, completing the electrical circuit. Continued
  • 30.
  • 31.
  • 32.
  • 33. Figure 35–11 PTC circuit protectors are used extensively in the power distribution center of this Chrysler vehicle. Continued
  • 34.
  • 35.
  • 36.
  • 37.
  • 38.
  • 39. Figure 35–13 Some terminals have seals attached to help seal the electrical connections. Continued
  • 40.
  • 41.
  • 42.
  • 43.
  • 44.
  • 45.
  • 46.
  • 47.
  • 48.
  • 49. Figure 35–21 A butane torch especially designed for use on heat shrink applies heat without an open flame, which could cause damage. Continued
  • 50.
  • 51.
  • 52.
  • 53.
  • 54. Most electrical wiring is protected with a plastic convoluted conduit, which comes in many different grades depending on the temperature of the surrounding area. A painted stripe usually indicates that the conduit is designed for high-temperature applications and is used where it would be placed on or near the engine. Do not use inexpensive conduit around wiring that will be exposed to temperatures higher than 200°F (85°C). What Does the Stripe on the Plastic Conduit Mean? Figure 35–24 The color stripe on the side of the convoluted conduit indicates that the conduit is designed for high-temperature applications.
  • 55.
  • 56.
  • 57. end