Engine Wiring Harness

Installing engine wiring harness is an essential task when it comes to upgrading or replacing the electrical system in your vehicle. Wiring harnesses are used to connect various electrical components in your car, such as the stereo, speakers, lights, and more. Installing a wiring harness may seem intimidating, but with the right tools and a basic understanding of electrical systems, it can be a straightforward process. Here are the steps to guide you through installing a car engine wiring harness.

1. Prepare your tools and materials: Before you begin the installation, gather all the necessary tools and materials. You will need a wiring harness kit specific to your car model, wire strippers, crimping tools, electrical tape, zip ties, and a wiring diagram or instruction manual.

2. Disconnect the battery: To avoid any electrical hazards, start by disconnecting the negative terminal of your vehicle's battery. This will prevent any accidental short circuits during the installation process.

3. Identify the wires: The first step is to identify the wires that you need to connect. The wiring harness kit you purchased should come with a wiring diagram or instruction manual that specifies the color coding for each wire. Match each wire to its corresponding component or location in your vehicle.

4. Remove the old wiring: If you're replacing an old wiring harness, remove it carefully without damaging any connected components. Cut the wires close to the connectors using wire cutters or strippers and save any connectors that you can reuse.

5. Connect the new wiring harness: Start by matching the wires from the harness kit to the wires you identified in your vehicle. Strip the ends of each wire using wire strippers and twist them together. It's essential to ensure the wires are securely connected before proceeding.

6. Crimp the connectors: Once the wires are twisted together, use crimping tools to attach connectors to each joint. Crimping provides a secure connection and prevents any wire from coming loose. Make sure to follow the instructions provided with your wiring harness kit for proper crimping techniques.

7. Secure the wires: After connecting all the wires, use electrical tape to wrap each joint and prevent any contact with other wires. This step ensures a secure and insulated connection. Additionally, use zip ties to bundle and secure the wiring harness neatly to prevent any interference with other vehicle components.

8. Test the connections: Before reassembling any removed components, test your connections to ensure proper functionality. Reconnect the vehicle's battery and check if all the connected electrical components are working as intended.

9.Reassemble and tidy up: Once all the connections are tested and working correctly, reassemble any removed components in reverse order. Make sure to route the wiring harness neatly and secure it in place using zip ties or tape.

Power distribution design
Vehicle power supply system design is reasonable, is directly related to the normal work of the auto electric parts or not and the safety of the whole vehicle, therefore, automotive wiring harness design basic starting point of the whole world is give priority to in order to safety. The whole electric system consists of three parts: the direct power supply system of the battery (usually called constant or 30). Pick up by this part of the power load is usually the car safety or important parts, the main aim is to provide electricity for the less as far as possible control, to ensure that these items even if the car won't start can also brief to work properly, for easy to site maintenance. For example: power supply of engine ECU and engine sensor, working power of fuel pump, power of ABS controller, diagnosis interface power, etc. The power supply system (commonly known as IG, 15 or ON) is controlled by the ignition switch. This distributor is basically used only when the engine is working, from the power of the generator to avoid the possibility of power supply for the battery. For example: instrument power supply, brake lamp power supply, airbag power supply, etc. When the engine starts off, the load is removed (commonly known as ACC power). This distributor is usually loaded with heavy load and does not need to work when the car is starting. Generally, there are cigarette power supply, air conditioning power supply, power supply, wiper power, etc.

Line protection design
The line protection is to protect the wire and protect the circuit. Protective devices mainly include fuse, circuit breaker and fuse link.
1. The selection principle of the fuse engine, ECU, ABS, etc., has great influence on the performance and safety of the whole vehicle. In addition, the electronic parts that are easily disturbed by other electrical equipment must be equipped with a single fuse. The engine sensor, all kinds of alarm signal lights and external lighting, horn and other electrical components have great influence on the performance and safety of the vehicle, but the electric load is not sensitive to the interference of each other. Therefore, this type of electrical load can be combined with each other to use a fuse. The electrical load of the normal electrical components set for the increase of comfort can be combined with each other to use a fuse. The fuse is divided into quick melting and slow melting. The main components of quick-melt fuse are fine tin wire, and the structure of the chip fuse is simple, reliable and robust and easy to detect, so it is widely adopted. The slow-melt fuse is actually a tin alloy sheet, and the fuse of this structure is usually strung into the circuit of the inductive load, such as the motor circuit. Resistive load and inductor load avoid using the same fuse. According to the maximum continuous working current calculation of the electrical components and the capacity of the fuse, according to the empirical formula, the rated capacity of the fuse is equal to 80% (or 70%) of the maximum working current of the circuit.

2. Circuit breaker
The most characteristic of the circuit breaker is recoverability, but its cost is higher and use less. The circuit breaker is usually a thermal-sensitive mechanical device, which USES the different thermal deformation of the two metals to close or connect the contact. A new type of circuit breaker, using PTC solid material as a flow protection element, is a positive temperature coefficient resistor, which is disconnected or connected according to the current or temperature. The maximum advantage of this protective element is that it can be automatically connected when the fault is out, and no manual adjustment and replacement is required.

3.The characteristics of fusible line fusible line is when the line through great overload current, fusible line can be in a certain period of time (usually 5 s or less) fuse, which cut off power supply, prevent to produce malignant accidents. The fusible line is also composed of conductor and insulating layer, and the insulation layer is generally chloro-sulfonated polyethylene material, because the insulation layer is thicker, so see. It's thicker than that of the same specification. Fuse wire is usually connected directly to the battery of the battery. The common nominal cross section of fusible line is 0.3mm2, 0.5mm2, 0.75mm2, 1.0mm2, 1.5mm2, and even the fusible line of more large sections, such as 8mm2. The length of wire segment of the fusible line is divided into (50 or 5) mm, (100 + or 10) mm, (150 + + 15) mm3. The fusible line should have obvious signs, and when it is fused, its mark shall still exist for replacement.