Rewiring a vehicle
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==Overview== | ==Overview== | ||
When completely rewiring a vehicle there are a few things that must be determined beforehand. First, one must decide if a prefabricated harness will be used, or if a custom harness will be made from scratch. In any case, the harness should be assembled into groups and cut within a reasonable distance to the right length, while leaving extra wire to account for routing. | When completely rewiring a vehicle there are a few things that must be determined beforehand. First, one must decide if a prefabricated harness will be used, or if a custom harness will be made from scratch. In any case, the harness should be assembled into groups and cut within a reasonable distance to the right length, while leaving extra wire to account for routing. | ||
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==Fuse requirements== | ==Fuse requirements== | ||
| − | + | For heavy draw accessories a [http://www.crankshaftcoalition.com/wiki/Relay_application_guide-_Bosch_relays '''relay'''] is the preferred method of wiring a circuit. Some things that can benefit from a relay: | |
| + | *Headlights | ||
| + | *Cooling fans | ||
| + | *Fuel pump | ||
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| + | For circuits having a high draw a circuit breaker may be substituted for a large capacity fuse. | ||
;Basic fuse requirements (from [[Media:Harness inst painless.pdf|Painless wiring]]): | ;Basic fuse requirements (from [[Media:Harness inst painless.pdf|Painless wiring]]): | ||
| − | + | {| class="wikitable" | |
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| − | + | ! Accessory !! Amp!!Accessory!!Amp | |
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| − | + | |Power windows||20|| Power antenna||10 | |
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| − | + | |Turn signals||15||Electric fan relay||5 | |
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| − | + | |Emergency flashers||15||AC/Heat relay||5 | |
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| − | + | | Electric fuel Pump||15 | |
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The fuse requirement and wire gauge has to take the accessory load into consideration. Using too small of a wire can let a wire burn even though the accessory load matches the fuse rating. Using too 'big' of a fuse can let a wire burn even if the wire gauge matches the load. | The fuse requirement and wire gauge has to take the accessory load into consideration. Using too small of a wire can let a wire burn even though the accessory load matches the fuse rating. Using too 'big' of a fuse can let a wire burn even if the wire gauge matches the load. | ||
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Whatever system approach you take, test for functionality, correct any errors you may find. | Whatever system approach you take, test for functionality, correct any errors you may find. | ||
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Fuse links, unlike fuses, do not just blow -- something major is wrong! And, it was wrong long enough to melt wire -- unlike a 5 amp radio fuse that sees a 7-amp spike and opens a few times a year. It took a 50, 70 or 100 amp short of a few seconds/minutes to melt the link -- not a small issue. Find out why! | Fuse links, unlike fuses, do not just blow -- something major is wrong! And, it was wrong long enough to melt wire -- unlike a 5 amp radio fuse that sees a 7-amp spike and opens a few times a year. It took a 50, 70 or 100 amp short of a few seconds/minutes to melt the link -- not a small issue. Find out why! | ||
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In either case, a maxi and fuse link do the same job -- a 70-amp maxi is the same as a 70-amp link. What is important on either is to never install them inside a passenger compartment. They do their job by heating and melting, and can cause fires to interior parts, melt plastic parts, and create toxic fumes in a closed compartment. Always install them in the engine bay away from fuel, hydraulic, or other flammables. | In either case, a maxi and fuse link do the same job -- a 70-amp maxi is the same as a 70-amp link. What is important on either is to never install them inside a passenger compartment. They do their job by heating and melting, and can cause fires to interior parts, melt plastic parts, and create toxic fumes in a closed compartment. Always install them in the engine bay away from fuel, hydraulic, or other flammables. | ||
| − | While some wiring harnesses recommend the main power come off the starter live connection, running the wire straight to a single insulated battery terminal post can be a better way to go. Such a case would be an off-road vehicle where water or mud could cause problems if the main power wire is connected to the | + | While some wiring harnesses recommend the main power come off the starter live connection, running the wire straight to a single insulated battery terminal post can be a better way to go. Such a case would be an off-road vehicle where water or mud could cause problems if the main power wire is connected to the start |
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