| Electrical System and Winch -- Wiring Inspection |
From "Weekend Mechanic"
episode WKM-207 |
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In this episode, Weekend Mechanic Bruce Bonebrake upgrades the electrical system on a Jeep, and installs a winch to enhance the vehicle's off-road capabilities. The problem: The Jeep has had several after-market electrical accessories installed, including a CB radio and off-road lights. The amateur wiring done for these installations has left a tangle of wires and a number of unreliable wire-connections . Sturdy connections and secure wiring is especially important for off-road vehicles , since the wiring will have to withstand rough road conditions, shaking, jarring , etc. The first task is to track down all of the wires to determine what each is connected to. Once that's done, the worn-out wiring can be replaced, and all of the accessory wires routed to a single fuse-panel. Once the electrical work is done, a winch will be installed on the Jeep, making use of the new fuse box for its power supply. DIY Difficulty Rating for Repair: This job is not as difficult or complex as many people might think. We gave it a difficulty rating of 3 on a 5-point intermediate-level scale. Allow yourself about a day and a half to finish both the electrical work and the winch installation. 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 that 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. In addition to standard auto-mechanic's tools, some of the specialty tools that will be needed for this project include new wires and terminals, split loom, zip ties, heat-shrink tubing and a heat gun. An air-ratchet is optional, but will help speed the assembly process.
Wiring Inspection
- This vehicle has an old battery with multiple wires connected to the positive terminals (figure A) -- the product of multiple after-market accessories being previously installed. Accessories already installed include off-road lights, stereo amplifier, CB radio and alarm system. This has resulted in a tangle of wires under the hood, and an overloaded terminal on the positive side of the battery.
- Inline fuses have been installed in various locations (figure B), but at this point it's difficult to tell what the fuses and lines lead to.
- Some wires have become tangled and twisted, and some connections are simply taped or have come loose altogether (figure C).
- The wiring harness itself has become twisted and wrapped around some engine parts (figure D). Before the new winch can be installed safely, the wiring problems need to be addressed.
- As part of the electrical upgrade, a new and larger battery will be installed. Also , an accessory fuse panel (figure E) will be added to accommodate and consolidate the wiring for all of the accessories, including the new winch.
- It's important to find a secure and safe mounting location for the new fuse box . The location must not interfere with other working parts, and must allow for wiring to be attached without causing problems. It should also be located close to the battery if possible, for least electrical resistance. For our fuse-box, we opted to mount it to the inner surface of the fender (figure F).
- Before beginning any electrical work, it's important to disconnect the cable from the negative side of the vehicle's battery (figure G). Make certain that you disconnect the cable from the negative side. Touching a metal wrench to the positive terminal could cause a dangerous arc, spark or even a battery-explosion.
In the segment that follows, the wires are tracked to their sources, and work begins on the electrical upgrade.
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
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