Automotive wire harness assembly and maintenance process

Before assembling the automotive wiring harness, you must thoroughly familiarize yourself with the circuit diagrams and circuit diagrams, and familiarize yourself with the location of the body electrical installations and the specific structure of the vehicle body, and understand the control methods of the various parts of the work units in order to correctly connect the wiring. Below, Hooha talks about the process of assembly and maintenance of automotive wiring harness and hopes to help everyone.

First, when the harness is assembled, do not pull the harness too tight (especially in the transverse direction) to avoid the position of the fixed point of the harness being misaligned due to the jogging state of the traveling vehicle. As a result, the distance between the two fixed points increases instantaneously, and thus the length increases. The wiring harness causes the internal contacts of the wiring harness to pull off/virtually connect, change the wire parameters, and even break the wires.

Second, after the automobile wiring harness is assembled, there must be sufficient clearance around it to ensure that it is not pressed by other components and is not picked up by other components and its fasteners. Avoid faults such as pinching, abrasion, or cracking of the wire harness insulation and grounding.

Third, do not arrange connectors of the same type and color in the adjacent position. Avoid mis-insertion, damage to harnesses and electrical appliances during assembly.

Fourth, the connector is arranged in an easy-to-find position, in a position where the hand and the tool are easy to operate. In order to facilitate inspection and maintenance, it is necessary to consider the length of the lead wires of the electrical device according to the actual assembly conditions. If the electrical device is installed in the surface easy-to-operate position, the wire can be directly connected to the connector; if the installation position of the electrical device is hidden, and the subsequent maintenance is difficult to disassemble, the electrical device can be provided with wires as required. The length is appropriately increased so that the connector is arranged at a position convenient for inspection and maintenance.

Fifth, after the engine is assembled, the connectors should be connected very conveniently. This mainly refers to the connection of the engine wiring harness and engine compartment harness, and the engine controller ECU. Since the engine is in a vibrating state during operation, in order to make the engine wiring harness, the wiring harness of the cabin, and the ECU connect reliably, it is not only necessary to appropriately increase the length of the engine harness (generally the length is not less than 50mm), but also needs to be 100mm before the connector of the engine harness end. Add a fixed point to the left and right, and fix it on the vehicle body to avoid the transmission of engine vibration, resulting in the looseness of the connector and the virtual connection of the terminals.

6. If the wire harness passes through the sheet metal hole from the cab to the outside, the external harness must be lower than the wire hole to avoid the possibility of entering the room after the wire is dropped or spilled.

When the four-door wiring harness and the cabin wiring harness are connected, the over-hole in the door is lower than the side-by-side hole in the body side. If there is liquid on the door harness rubber sleeve, it may only enter the door and cannot enter the cab.

Eight, the connector and the wiring harness can be easily passed through the body's wire holes to facilitate assembly and save installation time.

9. Electrical devices installed at the instrument panel: Connector connectors for instrument clusters, switch panels, air-conditioning panels, sound systems, and display panels that are connected to the instrument panel wiring harness should have a sufficient length for actual use. According to the installation depth of the electrical device, the position of the socket, the direction of the opening of the socket, and the rear space of the electrical component after assembly, the reserved length of the joint on the harness is appropriately increased according to the convenience of the operation.

Tenth, the reserved length of the four-switch harness, the ceiling lamp on the indoor ceiling and the reserved length of the switch harness connector are also calculated with reference to the calculation method of the electrical device installed at the instrument panel.

Eleventh, need to consider that in the inserting direction of the connector, there must be more than twice the length of the plug-to-insert direction.

Twelve, the length of the acoustic antenna harness must also be considered to allow sufficient length for assembly.

XIII. For other plug-in harness connectors, consider the need to reserve the length of the harness for easy disassembly. For electric devices installed in the surface position, installed in the lower part of the seat (opening the seat can be operated), pay under the dashboard (operation panel can be disassembled) or two wire harness assembly and other situations, may not reserve length, Refer to the actual measurement results and connector design.