In simple terms, automotive wire is a type of wire specifically designed for use in automotive wiring harnesses.
Different types of automotive wires and cables serve various purposes, and the most common ones you'll encounter include brake wires, speaker wires, primary wires, and battery cables.
Choosing the wrong wire for a particular application can lead to system failures in your car. Additionally, improper wiring could cause serious risks, including engine fires.
As a side note, any wire thicker than gauge 8 is typically referred to as a cable.
This is one of the most common wires found in any vehicle's wiring system. The GPT wire features a multi-strand core with flexible insulation, allowing it to fit into tight spaces. Primarily used for internal wiring, GPT wires should not be exposed to outdoor conditions for extended periods. They can withstand temperatures up to 176°F and resist chemicals, acids, and oils.
Unlike primary wires, motor wires have finer copper strands and more delicate insulation. They are typically designed to withstand up to 600 volts and temperatures as high as 221°F. Motor wires can also handle higher voltages without issues.
TXL wires have a single-strand copper conductor and are insulated with cross-linked polyethylene (XLPE). GXL wires are similar but also have XLPE insulation. SXL wires feature a bare copper conductor with XLPE protection. The use of XLPE insulation provides these wires with superior aging, abrasion, and heat resistance.
The thickness of the insulation varies by wire type: TXL has the thinnest insulation, GXL offers a medium thickness, and SXL has the thickest insulation, making it more suitable for heavy-duty applications such as industrial or racing vehicles. TXL wires are also popular in racing vehicles due to their lightweight design, which helps reduce weight.
Battery cables connect the battery to the ground and the vehicle's electrical system. These cables are typically thicker than most wires to handle the power demands of the battery.
Speaker wires transmit audio signals from the stereo receiver to the speakers. Typically used for low-voltage applications, it's important to properly connect the positive and negative terminals to ensure optimal sound quality.
Trailer wires are specialized primary wires tailored for use in trailers. They are often color-coded with brown, green, white, and yellow to indicate specific connections.
DIFFERENCE BETWEEN HOUSE WIRE AND AUTOMOTIVE WIRE
Automotive wires are designed to withstand the harsh conditions found within vehicles. For example, they are used in the engine, where house wires could easily be damaged by exposure to battery acid.
In contrast, automotive wires are built to endure high temperatures and resist chemical corrosion. They also feature a more durable and secure jacket while maintaining greater flexibility than house wires.
A common mistake people make is using house wires for automotive applications simply because they are cheaper. Even if a house wire meets the required current-carrying capacity, it doesn't account for the other critical factors, such as resistance to extreme temperatures and chemicals, which automotive wires are specifically engineered to handle.
COMMON VEHICLE WIRE DAMAGES
Automotive wiring can suffer from several types of damage, including:
SHORT CIRCUIT
A short circuit occurs when the wiring to the ground or electrical power source is compromised, causing certain components in the circuit to malfunction or operate partially. The severity of the issue depends on where the wiring is damaged and how quickly it occurs.
OPEN CIRCUIT
An open circuit happens when a wire is cut or disconnected, preventing the current from flowing from one end of the circuit to the other. This results in an incomplete circuit and a loss of functionality.
HIGH RESISTANCE
High resistance can obstruct the flow of current, leading to malfunctions in electrical components. This is often caused by improperly connected wires or corroded wires and components.
SIGNS YOUR CAR HAS DAMAGED WIRING
Wires in your vehicle serve as conduits, allowing the safe passage of electricity throughout various circuits. If a wire malfunctions, your car will display signs related to the electrical components that rely on that particular wiring.
MALFUNCTIONING VEHICLE ELECTRICAL COMPONENTS
Damaged wiring can lead to various electrical issues, such as a non-functional radio or malfunctioning lights.
FUSE KEEPS BLOWING
Fuses are designed to blow when excess voltage flows through a circuit. If your vehicle has a shorted wire, it can cause an overload of electricity, triggering the fuse to blow.
CAR WON'T START
Wiring problems can often prevent your car from starting. This could be due to issues like a corroded PCM ground wire or a damaged wire in the starting circuit.
HOW TO CHOOSE VEHICLE WIRES
When selecting a wire for your project, several key factors should guide your decision-making process.
WIRE SIZE
Wires are measured by gauge size, with a lower number indicating a thicker wire. For example, a 10-gauge wire is thicker than a 20-gauge wire. The appropriate gauge size depends on the amount of current the wire needs to carry and the distance between the power source and the component. Thicker wires are needed for higher current demands or longer distances to ensure efficient power transmission.
If you're doing repairs, consult the vehicle's technical manual to avoid costly mistakes. The manual typically specifies the exact wire gauge required for each component, helping you select the right size.
WIRE AMPERAGE
Amperage refers to the maximum amount of electricity a wire can safely carry. Before purchasing any wire, always check the label to verify its amperage rating. Overloading a wire can cause it to short-circuit, damage important systems, stall equipment, or even cause a fire. It is crucial to ensure that the wire's amperage rating is suitable for the application.
Additionally, be aware of the relays, circuits, breakers, fuses, and any overload protection mechanisms required for your wiring project. Using the right automotive wiring
CONNECTORS is also essential, as excessive amperage can damage connectors and lead to system failures.
WIRE MATERIALS: COPPER OR ALUMINUM
Electrical cables and automotive wire materials are mainly available in two forms; aluminum and copper. Copper wires are often the right choice for automotive wire harness applications. Copper wires are more flexible and conductive compared to aluminum. Also, copper wires are less likely to corrode.
Aluminum wires, on the other hand, are considered lighter and cheaper. However, they are less durable and more susceptible to corrosion. Also, over time, aluminum wires are likely to develop electrical resistance.
WIRE CORE: STRANDED VS. SOLID
Solid wire is primarily used in the wiring harness industry and for home applications. It is not ideal for automotive use unless you intend to use it for non-flexible purposes, such as bail wires. For automotive wiring, flexibility is crucial, which is why stranded wire is the preferred choice. Stranded wire is more flexible and capable of bending repeatedly without breaking, whereas solid core wire is less adaptable and may crack under continuous bending.
INSULATION: CROSS-LINKED VS. PVC
PVC Insulation
PVC insulation is created by heating the PVC material, which is then extruded through a die to form the insulating layer. The insulation is melted and applied through a heat source, giving it its final form. PVC automotive wires are categorized into three types:
- GPT: Rated for 80°C, used for general circuit wiring.
- HDT: Also rated for 80°C, designed for heavy-duty applications.
- TWP: Rated for 105°C, often used for thin-wall automotive wiring, and is lead-free.
Cross-Linked Insulation
Cross-linked insulation is created by extruding polyethylene while applying high pressure and heat, which causes the polymer chains to bond, forming a stronger material. Cross-linked automotive wires can handle much higher temperatures than PVC wires, making them more suitable for the demanding environment of automotive wiring harnesses. The three main types of cross-linked wires include:
- GXL: Rated for 125°C, considered thin-walled, and works well with standard automotive connectors.
- SXL: Also rated for 125°C, with a standard wall thickness for general applications.
- TXL: Rated for 125°C, considered fragile-walled, and is ideal for applications that require smaller sizes and minimal weight, such as wire harnesses.
WIRE COLORING, STRIPING, AND PRINTING
Automotive harness wires come in a wide range of colors, offering a simple method for organizing cables based on their intended use. By assigning specific colors to different wires, you can easily track and identify them, streamlining tasks and repairs. Many industries have their own standard color systems for wires, and you can even expand the color scheme by adding stripes for further differentiation.
Additionally, some wires come with printed labels indicating their specific function, providing further clarity. This makes it easier to sort wires quickly and efficiently, whether you're conducting repairs or working on new construction. Developing a color code for future wire stripping tasks can save time and improve organization.
CONNECTIONS
There are two primary types of automotive wire connections: solderless and soldered.
Solderless connections are often considered the quickest and easiest way to terminate wires. These connections include components like ring terminals, spade terminals, and quick disconnects, which can be easily crimped onto the wire. To ensure a secure connection, it's important to learn the correct crimping technique. Although solderless connections are fast, they may not always be as durable as soldered connections. To improve their longevity, strain relief accessories, such as auto wiring harness tape or heat shrink tubing, can be added.
Soldered connections, while more reliable and durable, are more challenging to install. They require a high level of precision and can be prone to error. Despite their strength, many professionals today prefer solderless connections due to the ease of use and the variety of options available. Soldered connections are less commonly used in automotive wiring due to the difficulty in ensuring consistent quality during installation.
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