Automobile wire harnesses are usually subjected to extreme conditions. The harness is fastened to the engine and chassis, which subjects the harness to excessive heat, cold and vibration. These conditions often cause the wire harness to stretch and contract causing undue stress, sometimes resulting in a broken wire. Corrosion also plays a big part in damaging an engine wire harness. Rainwater from the tires splashes up onto the engine and wire harness, leading to corroded terminals and wires. The corrosion will weaken the copper strands, eventually causing the wire to break. You only need few simple hand tools in order needed to repair a broken electrical wire in your engine harness.
Things You'll Need
- Wire cutters
- Wire strippers
- Black tape
- Soldering iron
- 16-gauge wire
Disconnect the negative terminal on the battery. Place the cable and connector in a location so it will not accidentally move and contact the battery post.
Locate the two ends of the broken wire. Inspect the wire ends for corrosion. If corrosion is found, remove the damaged copper until clean, shiny copper is revealed. Measure the distance between the two ends, and cut a piece of new wire 3 inches longer than needed. For instance, if there is a 3-inch gap between the wire ends, cut a piece of wire 6 inches long.
Use the wire strippers to strip 1 inch of insulation from the ends of the broken wire. Strip 1 inch of insulation from the ends of the new wire. Turn the soldering iron on and allow it to come to temperature.
Grab one end of the broken wire and twist the strands in a clockwise direction until they are tight. Twist the strands on the new wire so they are tight. Place the two exposed ends together so they create an “X”. Twist the new wire around the broken wire and wrap it toward the broken wire insulation. Twist the broken wire around the new wire and wrap it toward the new wire insulation. Twist the ends together on the other splice area. Place the soldering iron on the exposed pieces of copper for three to five seconds. Touch the solder close to the solder iron tip. As the copper wire heats up, the solder will be drawn into the copper strands. Continue feeding solder into the wire until the wire strands are covered with copper. Do not blow on the solder connection. Do not move the solder connection while the solder is in its liquid state. Allow the solder connection to cool. Repeat on the other solder splice.
Wrap the solder connections with black electrical tape.
- Photo Credit Jupiterimages/Photos.com/Getty Images
How to Repair Jayco Camper Cables
Jayco camping trailers, which first came on the market in 1968, use a winch and a system of cables, pulleys, drive slugs,...
How Take Out an Honda Engine
Removing a Honda engine is much easier than putting it back in, especially if you do not have to remember how you...
How to Wire an Electrical Outlet With Red, White, & Black Wires
The cables coming into an outlet, or receptacle, box typically have hot black conductors, neutral white conductors and bare copper ground wires....
How to Fix a Broken Electrical Wire in a House
Home repairs sometimes require a professional, but hiring a professional is not always practical. Repairing wires in your home can be one...
How to Connect End Caps on Electrical Wire
Connecting end caps, or wire nuts as they are called in the industry, is one of the safest ways to terminate an...
How to Repair an Electric Wire Pierced by a Screw
Remodeling sometimes involves working with fasteners and tools near electrical lines. Occasionally even the most seasoned professional will damage an electrical line....
How to Repair a Wire Harness
Repairing wire harnesses normally revolves around replacement of damaged pins or wiring. Given that the harness shell is typically very durable, the...
How to Put a New Wiring Harness In an MGB
Putting a new wiring harness in an MGB was a consideration made by the car's company. Most of the wires on the...
How to Make an Engine Wiring Harness
Modern vehicles are laced with wires. In the engine bay, there is no shortage of wire harnesses connecting multiple devices together. Making...
How to Repair Electrical Wire Insulation
Electrical wire insulation for lamp and appliance cords is made from flexible polyvinyl chloride, and electrical house wiring insulation consists of a...