DIY Network

Window & Door-Lock Upgrade -- Wiring, Part 2 From "Weekend Mechanic" episode WKM-108

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Figure A Figure B Figure C Figure D Figure E Figure F Figure G Figure H Figure I Figure J Figure K Figure L Figure M Figure N Figure O Figure P Figure Q Figure R Figure S

With the power-window and power door-lock assemblies installed, and the wiring harnesses in place, the final phase of this upgrade project is the completion of the electrical wiring and re-assembly of the door.

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 will also be variations among different various after-market kits. Always consult your vehicle's service manual when undertaking significant automotive repairs. Follow the procedures, diagrams and safety precautions that come with the kit you select.

Safety Alert: To avoid electrical shock or equipment damage, disconnect the vehicle's negative battery cable before beginning any electrical work on the vehicle.

• To install the soldered terminals on the plug connector, first strip the ends of the wires back about 1/4-inch.
  
  
  
  
• Connect the terminal to the bare wire (figure A).
  
  
  
  
• Crimp the connection using a crimping tool (figure B). Standard crimping tools have three crimping positions. For our application, we used the first position to make this connection.
  
  
  
  
• Crimping the connection might be sufficient, but since these are solder-type terminals, we secured the connection by soldering (figure C). A soldered connection is more reliable and will typically last longer.

  Important: Be sure to use rosin-core solder, which is designed for electrical work.
  
  
  
  

• Allow the soldered terminals to cool, then insert them into the plug connector.
  
  
  
  
• With the soldered connections in place, the connection of wires to the plug connectors is complete (figure D).
  
  
  
  
• Now, simply plug the connections together (figure E), following the wiring instructions that come with your kit. These connectors will attach to the door-switches on the driver-side and passenger-side doors. This wiring should be supplied with power only when the ignition key is turned on.
  
  
  
  
• The next step is to install a dual relay that controls the lock and unlock functions (figure F). This is one of the dash-mounted connections required in this upgrade.
  
  
  
  
• Check the configuration of the terminals on the relay and relay-connector, make sure they match, then plug the two components together (figure G).
  
  
  
  
• Mount the relay and connector module under the dash in a convenient but out-of-the-way location (figure H). The relay in our kit has a mounting tab built in.
  
  
  
  
• The location we selected for mounting the relay was also a suitable location for mounting the control module for the keyless entry system. The power feed for the keyless entry system must be connected to the main ignition source. Strip back about 1/2-inch of the ignition wire and separate it (figure I).
  
  
  
  
• Strip the power-feed wire and fit it into the slot you made in the ignition wire.
  
  
  
  
• Once the power-feed wire is in place, secure the connection by soldering (figure J).
  
  
  
  
  
  
  
  
• With the basic wiring complete and the battery re-connected, check to make sure that the switches are working and the power windows and locks are operating (figure K).
  
  
  
  
• Make certain that the window-control mechanism (figure L) isn't impinging on any of the newly installed hardware or wiring as it operates.
  
  
  
  
  
• The final phase of the upgrade, prior to re-assembly of the door, is to mount the switch-plates. Our kit came with a template for marking the hole for the switches (figure M). Mount the switches in any convenient location on the door panel. Typically they are mounted over the old crank-handle hole.
  
  
  
  
  
• Once you've selected a location, drill the screw-holes, then use a jig-saw to cut out the hole (figure N).
  
  
  
  
  
• To fit the control switches into the cover plate, simply run the harness through the plate from the front (figure O), and snap the switches into place.
  
  
  
  
  
• Run the harnesses through the newly cut hole in the door panel, and attach the cover plate from the rear of the panel with screws (figure P).
  
  
  
  
  
• To prepare for re-assembly, replace the dust-shield that was removed earlier from inside the door (figure Q).
  
  
  
  
  
• Re-install the audio speakers if any were removed earlier.
  
  
  
  
  
• Connect the switches and the harness in the door (figure R), making sure the connections are placed and oriented in the right way.
  
  
  
  
  
• Carefully replace the door panel (figure S), making sure to seat the plastic door fasteners in their corresponding slots in the door.
  
  
  
  
  
• Replace the screws and any other mounting hardware to secure the panel.

Safety Alert: When working with wiring beneath the dash, do not tamper with any existing wiring in yellow harnesses. These are the wires that control the air-bag deployment system on vehicles that are so equipped. Tampering with these wires could cause the air-bags to deploy.

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