DIY Network

Electrical System and Winch -- Wiring Assessment From "Weekend Mechanic" episode WKM-207

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Figure A Figure B Figure C Figure D Figure E Figure F Figure G

Wiring Assessment

With the preliminary inspection of the wiring done, the next phase in the project is to track the existing wires their sources, and begin work on the electrical upgrade.

Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit or replacement parts you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

Steps:

• Once you've disconnected the vehicles negative battery cable, begin by taking the accessory wires loose at the positive battery terminal.
  
  
  
• Begin snipping the plastic wire-ties that were used previously to hold the wiring harness together (figure A). This will make it easier to determine where each of the individual wire leads. Use caution to cut only the ties, not the wires themselves.

  Important: As you cut off the wire ties, use care not to lose track of them. Avoid letting the discarded plastic ties fall into the engine where they could cause problems with moving parts.
  
  
  

• The process of disassembling the wiring harness revealed a cracked fuse-holder (figure B). This was installed previously as a fuse for the after-market stereo amplifier. Since this fuse is too big to fit in the new fuse panel, the holder will be replaced later.
  
  
  
• Continue loosening the wires, concentrating only on the power-wires that were connected directly to the battery (figure C). The new wiring harness will follow the factory wiring-harness as closely as possible.
  
  
  
• The old split-loom will be replaced as well, so remove the old one. It slides off easily.
  
  
  
• The next step is to pull the wires you've identified through the firewall of the vehicle to determine where they are connected. Any inline fuses previously installed will probably need to be cut off so that the wires will fit through the firewall.
  
  
  
• As you hold onto the under-the-hood sections of wire, have an assistant pull the wires through into the cab of the vehicle (figure D). Follow each wire carefully to find which circuit it's connected to.
  
  
  
• Inside the cab, we discovered sections of wires that had been spliced using screw-on wire nuts (figure E). We opted to replace the spliced wiring by running entirely new wires from each accessory or switch inside the cab out to the new fuse box. This will provide a more stable connection for each set of wiring.
  
  
  
• The power wires leading to dash switches for off-road lights and other accessories are all disconnected (figure F).
  
  
  
• The wire supplying the CB radio has an inline fuse and plug (figure G). The existing wiring had the wires connected improperly (without proper ground) which would have prevented the CB from working. This situation will be corrected later -- with a properly wired and soldered connection -- as part of the re-wiring process. The plug itself will be salvaged and reused since it is brand-specific for the already installed CB radio.

RESOURCES :

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896

Jeep Owner's Bible: A Hands-On Guide to Getting the Most from Your Jeep
Model: 0837601541
Author: Moses Ludel
(1992)

To order this title from Amazon.com, click here.

Bentley Publishers

The Jeep Bible: Written Personally for the Jeep Cult!
Model: 0961847344
Author: Granville King and Willie Worthy
(1997)

To order this title from Amazon.com, click here.

Quellen Company