AURETR010 Repair wiring harnesses and

looms
 Learning Outcomes
After this presentation, you be able to demonstrate knowledge
to complete the tasks outlined in the elements, performance
criteria and foundation skills of this unit, including knowledge
of the following learning outcomes :
• Work health and safety (WHS) and occupational health and
safety (OHS) requirements relating to repairing wiring
harnesses and looms
• Environmental requirements
• Location and content of workplace procedures and
manufacturer specifications relating to wiring
harnesses and looms
• Types of wiring systems found in vehicles
 Learning Outcomes
• Testing procedures
• Removal procedures for wiring harnesses and looms
• Repair procedures of wiring harnesses and looms
• Post-repair testing procedures of wiring harnesses and looms
Work health and safety (WHS) and
occupational health and safety (OHS)
requirements relating to repairing wiring
harnesses and looms
• Procedures for:
– Using safety data sheets (SDS)
– Selecting and using personal protective equipment
(PPE)
– Identifying firefighting equipment
– Safely handling hazardous materials
and toxic substances
– Following soldering equipment safe
operating procedures
 Workplace Health and Safety
(WHS) Requirements
Personal safety
• Eye protection
– To be safe, wear suitable eye protection whenever
you are working in the workshop
– Eye protection must always be worn

Various types of eye protection:

safety (splash) goggles, face
shield, and safety glasses.
Workplace Health and Safety
(WHS) Requirements (Cont.)
Personal safety
• Respiratory masks should be worn when working
with components containing asbestos or other
toxic substances that contain toxic fumes
Workplace Health and Safety
(WHS) Requirements (Cont.)
Personal safety
• Tie back long hair
• Wear properly fitting clothes
• Jewellery can get caught in rotating objects
• Proper safety shoes or boots must be worn at all
times
Personal Safety Video

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Workplace Health and Safety
(WHS) Requirements (Cont.)
Venting the Engine Exhaust
• Whenever you need to have the engine running for
diagnosis or service, the engine’s exhaust must be
vented to the outside.
• Carbon monoxide (CO) is present in the exhaust.
CO is an odourless, tasteless, and colourless
deadly gas.
• Inhaling CO can cause brain damage and, in
severe cases, death.
• Early symptoms of CO poisoning include
headaches, nausea, and fatigue.
Workplace Health and Safety
(WHS) Requirements (Cont.)
Venting the Engine Exhaust
• Most workshops have an exhaust ventilation
system; always use it.
• These systems collect the engine’s exhaust and
release it to the outside air
Workplace Health and Safety
(WHS) Requirements (Cont.)
Using safety data sheets (SDS)
• Always read the label and SDS before using
unfamiliar substances
• Be familiar with the dangers of various substances
used in the workshop
• Follow all environmental policies for proper
disposal
SDS Video

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Workplace Health and Safety
(WHS) Requirements (Cont.)
Electrical Safety
• Disconnect the vehicle battery whenever possible
• Disconnect negative first then positive
• Reconnect positive first then negative
• Remove all jewelry when working on the electrical
system
• Batteries contain acid and can cause severe
injuries to eyes and skin
Workplace Health and Safety (WHS)
Requirements (Cont.)
Fire Hazards and Prevention
• Electrical system failures are common cause of car
fires.
• Electrical wiring runs throughout the entire car;
through channels, into doors, under the carpet and
through powered and heated seats, just to name a
few places where a stray, unnoticed frayed wire
could cause a fire.
Workplace Health and Safety (WHS)
Requirements (Cont.)
Fire Hazards and Prevention
• Protection devices such as fuses, fusible links and
circuit breakers provide an element of safety in
case of arcs or overloaded wiring, but sometimes
components breakdown, shoddy repairs or poor
installation of aftermarket equipment can defeat
these safeguards.
Workplace Health and Safety (WHS)
Requirements (Cont.)
Fire Hazards and Prevention

Burnt wiring caused by a short

Workplace Health and Safety (WHS)
Requirements (Cont.)
Fire Hazards and Prevention
• Classes of Fires
– Class E - Electrical Equipment
– A Class E fire is one that involves electrical equipment.
Workplace Health and Safety (WHS)
Requirements (Cont.)
Fire Hazards and Prevention
• Steps in Using a Fire Extinguisher
1. Pull pin from handle
2. Aim nozzle at base of fire
3. Squeeze handle
4. Sweep entire width of fire
Workplace Health and Safety (WHS)
Requirements (Cont.)
Safely handling hazardous materials and toxic substances
• Caused by high concentrations of vapors, gases, or
dust
• Solvent vapors
Workplace Health and Safety (WHS)
Requirements (Cont.)
Safely handling hazardous materials and toxic substances
• Solder, flux and cleaners
– Wear eye protection. Solder can “spit”.
– Use rosin-free and lead-free solders wherever possible.
– Keep cleaning solvents in dispensing bottles.
– Always wash your hands with soap and water after soldering.
• Lead exposure
– Lead can give rise to serious chronic health effects.
Exposure will primarily be through accidental ingestion from
your skin, wear gloves if directly handling solder. Limited
fumes may be generated by soldering.
Workplace Health and Safety (WHS)
Requirements (Cont.)
Safely handling hazardous materials and toxic substances
• Rosin exposure
– Rosin (colophony, ersin) is a resin contained in solder flux.
Flux generates the visible fumes seen during soldering.
Exposure to rosin can cause eye, throat and lung irritation,
nose bleeds and headaches. Repeated exposure can cause
respiratory and skin sensitisation, causing and aggravating
asthma. Rosin is a serious occupational health hazard.
Workplace Health and Safety (WHS)
Requirements (Cont.)
Safely handling hazardous materials and toxic substances
• Control of fumes
– Fume extraction should be through an enclosed hood
(preferred) or tip extraction.
– Ideally these should vent to the outside.
– Tip extract units that use filter boxes should include both
activated carbon and HEPA filters.
Workplace Health and Safety (WHS)
Requirements (Cont.)
Following soldering equipment safe operating procedures
• Never touch the element of the soldering
iron....400°C!
• Hold wires to be heated with tweezers or clamps.
• Keep the cleaning sponge wet during use.
• Always return the soldering iron to its stand when not
in use. Never put it down on the workbench.
• Turn unit off and unplug when not in use.
• Always wash your hands with soap and water after
soldering.
Environmental requirements,
• Procedures for trapping, storing and disposing
of hazardous materials and toxic substances
released during repair processes
Environmental requirements

Soldering Waste
• Soldering waste is considered hazardous.
• Discard solder and dross in a container with a lid.
• Used solder sponges and contaminated rags must
be disposed of as hazardous waste.
• The collection container should be metal and
labelled.
Location and content of workplace
procedures and manufacturer
specifications relating to wiring
harnesses and looms
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms
• Always refer to the vehicles manufactures
manual when repairing wiring harnesses and
looms faults.
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
• Service Information Sources
– Manufacturers service information
– General computer-based information systems
– Owner’s manuals
– Lubrication guides
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
• Screenshot from Alldata Service
Information System
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
• Service Information Sources
– Aftermarket suppliers guides and catalogs
– Hotline services
– International Automotive Technicians Network
(IATN)
– The internet
Using Service Information Video

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Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
• Steps for Using a Service Manual
– Select the appropriate manual for the vehicle
being serviced
– Use the table of contents to locate the
applicable section (Ignition Systems)
– Use the index at the front of the section to
locate the required information
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
• Steps for Using a Service Manual
– Carefully read the information and study the
illustrations and diagrams
– Follow the required steps and procedures
– Adhere to all of the given specifications and
safety precautions
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
Technical Service Bulletins
• Technical service bulletins (TSBs) are issued by
manufacturers to provide information to
technicians on unexpected problems, updated
parts, or changes to repair procedures that may
occur with a particular vehicle system, part, or
component.
• The typical TSB contains step-by-step procedures
and diagrams on how to identify if there is a fault
and perform an effective repair.
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
Technical Service Bulletins
• At the time of production, manufacturers prepare
service and technical information and attempt to
anticipate the information the technicians will
require to undertake service and repairs.
• Once the vehicle is in use, situations can arise
when particular components or repair procedures
may need either additional information or changes.
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
Technical Service Bulletins
• This is where TSBs are most useful. For example,
to provide details about a change to the procedure
to adjust the ignition timing.
• In this situation, the manufacturer would issue a
service bulletin explaining the problem and the
changes to the current procedure performed to
adjust the ignition timing.
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
Electrical Wiring Diagrams
• Also called schematics
• Does not show location or actual appearance of
components
• Symbols are used to represent
components
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
Electrical Wiring Diagrams
• Diagram may illustrate one system or one part of a
complex system
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
Using Wiring Diagrams
• One of the most important resources
• Shows relationships of circuits
• They illustrate:
– Wires by number or color
coding
– Wire cross-section size
– Ground connections
– Wire connection points
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
Using Wiring Diagrams
• Diagrams show:
– Reference wire continuation
– Location of splices
– Terminal designations
– Component symbols
– Switches
– Fuse designations
– Relay information
– Circuit continuation
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
Getting the Right Diagram
• Should be for the exact year, make, and model
• Refer to the VIN
• May have system specific diagrams
• Some vehicles have only total vehicle diagrams
Location and content of workplace procedures
and manufacturer specifications relating to
wiring harnesses and looms (Cont.)
Tracing a Circuit
• Identify components,
connectors, and wires
related to diagnosis
• Trace power through the
circuit with highlighters
• Identify power, ground,
loads, and controls
Types of wiring systems found in
vehicles
• Basic single wiring, including:
– Trailer harness
– Driving lights harness
– Accessory wiring harness
• Complex multi-wiring with varying wire gauges
• Controller area network databus (CAN-
bus) wiring, including:
– Twisted pair
– Shielded wiring
Types of wiring systems found in
vehicles
Wires
• Solid Wires
– Single strand conductors
• Stranded Wires
– Most common
Types of wiring systems found in
vehicles (Cont.)
Automotive wires

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Types of wiring systems found in
vehicles
Ground Wires
• All vehicles use ground wires between the engine
and body and/or between the body and the
negative terminal of the battery.
• The two types of ground wires are:
– Insulated copper wire
– Braided ground straps
• Braided grounds straps are uninsulated. It is not
necessary to insulate a ground strap because it
does not matter if it touches metal, as it already
attaches to ground.
Types of wiring systems found in
vehicles
Ground Wires
• Braided ground straps
are more flexible than
stranded wire.
• Because the engine will
move slightly on its
mounts, the braided
ground strap must be
able to flex without
breaking.
Types of wiring systems found in
vehicles (Cont.)
Harnesses
• A cable harness, also known as a wire harness,
wiring harness, cable assembly, wiring assembly or
wiring loom, is an assembly of electrical cables or
wires which transmit signals or electrical power.
• Different types of harnesses including
– Engine harness
– Body harness
– Trailer harness
– Driving light harness
– Accessory wiring harness
Types of wiring systems found in
vehicles (Cont.)
Trailer Harness
• A trailer connector is a
multi-pole electrical
connector between a towing
vehicle such as a car or
truck and a trailer.
• It is intended primarily to
supply automotive lighting
on the trailer, but also
provide management and
supply to other consumers
Types of wiring systems found in
vehicles (Cont.)
Trailer Harness
• Size standards established by SAE
– Called American Wire Gauge (AWG)
– 0 is largest size
– 40 is smallest size
• Metric sizes are the cross-sectional area of the
conductor
– Measured in square millimeters (mm²)
Types of wiring systems found in
vehicles (Cont.)
Trailer Harness

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Types of wiring systems found in
vehicles (Cont.)
Driving Lights Harness
• Driving light wiring
harnesses offer simple
driving light installations
with a pre-made harness
including all the relevant
clips, connectors and
switches
Types of wiring systems found in
vehicles (Cont.)
Driving Lights Harness

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Types of wiring systems found in
vehicles (Cont.)
Accessory Wiring Harness
• Harnesses are wiring assemblies for your
accessories that are bound by straps, lacing sleeves
or conduits.
• They prevent the wires within from sustaining
damage.
Types of wiring systems found in
vehicles (Cont.)
Accessory Wiring Harness

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Types of wiring systems found in
vehicles (Cont.)
Complex multi-wiring with varying wire gauges
• Size standards established
by SAE
– Called American Wire
Gauge (AWG)
– 0 is largest size
– 40 is smallest size
• Metric sizes are the cross-
sectional area of the
conductor
– Measured in square millimeters
(mm²)
Wire Size Video

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Types of wiring systems found in
vehicles (Cont.)
Complex multi-wiring with varying wire gauges
• There are several complex wiring harnesses in a
vehicle, in addition to the simple harnesses
(below).
• The engine compartment harness and the under-
dash harness are examples of complex harnesses
Types of wiring systems found in
vehicles (Cont.)
Complex multi-wiring with varying wire gauges
• A complex wiring
harness
Types of wiring systems found in
vehicles (Cont.)
Complex multi-wiring with varying wire gauges
• A complex harness serves many circuits, while a
simple harness services only a few circuits.
• Some individual circuit wires may branch out of a
complex harness to other areas of the vehicle.
Types of wiring systems found in
vehicles (Cont.)
Controller area network databus (CAN-bus) wiring –
Twisted pair
• A twisted pair is where two wires are twisted to
prevent electromagnetic radiation from affecting
the signals passing through the wires.
Types of wiring systems found in
vehicles (Cont.)
Controller area network databus (CAN-bus) wiring –
Twisted pair
• By twisting the two wires about once every inch
(9 to 16 times per foot), the interference is
cancelled by the adjacent wire
Types of wiring systems found in
vehicles (Cont.)
Controller area network databus (CAN-bus) wiring –
Shielded wiring
• Shielded wiring, like twisted wiring protects the
signal in the wiring from outside electrical
interference.
Types of wiring systems found in
vehicles (Cont.)
Controller area network databus (CAN-bus) wiring –
Shielded wiring
• The wiring in a vehicle’s CAN network often has
foil or a braided shielding protecting signal
integrity.
Testing procedures

• Accessing electrical terminals and using test

probes without damaging connectors, fuse
holders or wiring
• Testing wiring harnesses and looms, including
resistance and voltage drop and circuit
performance checks
• Visual and functional assessments, including:
– Component damage and wear
– Component corrosion
– Water and moisture ingress
Testing procedures
– Damaged insulation
– Frayed wires
– Burnt wiring
– Terminal and connector damage
Testing procedures

Accessing electrical terminals and using test probes

without damaging connectors, fuse holders or wiring.
• Always take the necessary precautions before
working on or around a vehicle’s electrical
system.
• Disconnect the battery before disconnecting
any electrical wire or component. (Ground
first, then positive)
• Take care when using test probes so as to not
damage connectors, fuse holders or wiring
Testing procedures (Cont.)

Backprobing
• Often testing electrical circuits requires a
technician to backprobe a connector to allow a test
lead to contact a terminal inside the connector.
Testing procedures (Cont.)

Backprobing
• To do this, a backprobing tool is slid into the
backside of the connector.
• Once the tool contacts the terminal of the desired
wire, the lead of a meter can be connected to the
metal portion of the probe that extends out of the
connector
Testing procedures (Cont.)

Backprobing
• A backprobing tool properly inserted into the back
of a connector.
Testing procedures (Cont.)

Backprobing
• The proper use of these tools will prevent damage
to the connector and its seals.
• Attempting to force a backprobe tool or meter lead
into a female terminal can damage the terminal
and expand its opening.
• This can create an open or intermittent connection
once the connector is reattached.
Backprobing Video

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Testing procedures (Cont.)

Testing wiring harnesses and looms

• Testing for Voltage Drop
– Voltage drop must be tested with the circuit energized
– Identifies unwanted resistance
– The voltage indicated is the amount of voltage used
between where the red lead is connected and where the
black lead is connected
Testing procedures (Cont.)

Testing wiring harnesses and looms

• Testing for Voltage Drop – Voltage Drop
Maximums
– 200 mV across a wire or connector
– 100 mV across a switch or relay contacts
– 100 mV at a ground connection
– Less than 50 mV across all sensor connections
Testing procedures (Cont.)

Testing wiring harnesses and looms

• Testing for Voltage Drop

Measuring the
voltage drop across
the battery post and
cable. It is easy to
see why the voltage
drop is high!
Testing procedures (Cont.)

Testing wiring harnesses and looms

• Measuring Current
– Tests the circuit under load
– Low current indicates high resistance
– DMM placed in series into the circuit
– Check the meter rating before attempting to measure
current flow

Checking a circuit using an ammeter

Testing procedures (Cont.)

Testing wiring harnesses and looms

• Measuring Resistance
– Tested with circuit off and disconnected
– Attempting to measure resistance on a powered circuit
may damage the meter

Measuring resistance
using an ohmmeter.
Note that the circuit
fuse is removed to de-
energize the circuit.
Testing procedures (Cont.)

Testing wiring harnesses and looms

• Measuring Resistance
– Resistance can be checked and compared to
specifications
– Can be caused by loose, damaged, or dirty connections
Testing procedures (Cont.)

Testing wiring harnesses and looms

• Continuity Tests
– Many DMMs have an audible alert when continuity is
present
– Can be used when testing for an intermittent problem
– Connect the DMM and move wiring and note when the
beeping stops
Electrical Measurement Video

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Testing procedures (Cont.)

Visual and functional assessments

• Component damage and wear
– The components will require repairs due to abuse,
improper disconnecting procedures, and exposure
potential to the element.
Testing procedures (Cont.)

Visual and functional assessments

• Switches
– Disconnect switch and check continuity between
terminals
Testing procedures (Cont.)

Visual and functional assessments

• Relay Testing Tips
– Never use a test light to test a computer- controlled relay
– Verify the presence of voltage at both the control and the
controlled side of the relay
– Verify the continuity of the relay coil
– Just because the relay “clicks” doesn’t mean it is good
Testing procedures (Cont.)

Visual and functional assessments

• Wiring
– Check insulation
• Broken, frayed, burnt, or damaged insulation can cause short
circuits
– Inspect ground connections
– Perform a voltage drop test on the wire

Damaged Wiring
Testing procedures (Cont.)

Visual and functional assessments

• Testing for Unwanted Resistance
– Typically caused by corrosion, loose or poor
connections, frayed or damaged wires
– Check voltage drop across the load
– Check sections of the circuit to find the unwanted
resistance

Corroded terminals.
Testing procedures (Cont.)

Visual and functional assessments

• Common Causes of Wiring Problems
– Corroded terminals
– Loose terminals
– Frayed, broken, or oil-soaked wires
– Faulty insulation

A damaged wiring harness

caused this open.
Removal procedures for wiring
harnesses and looms
• Accessing wiring and removing panels and
covers
• Removing and replacing components
• Disconnecting terminals from connectors
Removal procedures for wiring
harnesses and looms
Terminals and Connectors
• A terminal is a metal fastener attached to the end
of a wire, which makes the electrical connection.
• The term connector usually refers to the plastic
portion that snaps or connects together, making the
mechanical connection.
Removal procedures for wiring
harnesses and looms
Terminals and Connectors
• Separate a connector by opening the lock and
pulling the two apart
Removal procedures for wiring
harnesses and looms
Terminals and Connectors
• The secondary locks help retain the terminals in
the connector
Removal procedures for wiring
harnesses and looms (Cont.)
Replacing a Terminal
• Identify the type of
terminal and locking clips
• Remove the terminal
• Install and solder new
terminal
• Reinstall the terminal into
the connector

Depress the locking tang to

remove the terminal from the
connector.
Removal procedures for wiring
harnesses and looms (Cont.)
Replacing a Terminal
• Some terminals have seals attached to help seal
the electrical connections
Removal procedures for wiring
harnesses and looms (Cont.)
Replacing a Terminal
• Use a small removal tool, sometimes called a
pick, to release terminals from the connector

Push narrow pick between The locking tang in a

terminal and connector body. metri-pack connector.
Repair procedures of wiring harnesses and
looms
• Determining cable and terminal types and sizes
according to circuit current draw
• Wire soldering procedures
• Terminal crimping
• Replacing male and female terminals within a
connector housing
• Protecting and routing harness and
loom
Repair procedures of wiring
harnesses and looms
Wire Repair Considerations
• Type of repair required
• Ease of access to the damaged area
• Type of conductor
• Size of wire
• Circuit requirements
• Manufacturer’s recommendations
Repair procedures of wiring
harnesses and looms (Cont.)
Wire Repair
• Wrapping with electrical tape, heat shrink or
tubing
– Designed to insulate one circuit from another
Repair procedures of wiring
harnesses and looms (Cont.)
Wire Repair
• Solderless connectors
– Designed to be used in areas not subject to weather, dirt,
corrosion, or movement
Repair procedures of wiring
harnesses and looms (Cont.)
Wire Repair
• Soldering
– The best way to splice copper wires
Wire Stripping Video

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Repair procedures of wiring
harnesses and looms (Cont.)
Wire Repair
• Crimping
– Use correct size of
stripping opening
– Place wire into connector
and crimp connector
– Insert stripped end into
connector and crimp
– Use electrical tape or heat
shrink tube to provide
additional protection
Crimping Video

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Soldering Video

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Repair procedures of wiring
harnesses and looms (Cont.)
Protecting and routing harness and loom
• Electrical conduit covers and protects wiring.
Routing Harness & Loom Video

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Post-repair testing procedures of wiring
harnesses and looms

• Procedures for checking full operation of

associated electrical systems.
Post-repair testing procedures of
wiring harnesses and looms
• Verify the repair. Never assume that your work
solved the original problem.
• As with the post-repair of any problem, your post-
repair inspection should begin with trying to
duplicate the customer’s complaint.
• For wiring problems, this is done by operating the
electrical system.
• It is very important that during the operation test,
that the electrical system is fully tested for correct
operation.
Post-repair testing procedures of
wiring harnesses and looms
• Pay attention to these during the operation test.
• Check the electrical system for DTCs
• Vehicle is clean