Table of Contents
ACKNOWLEDGMENTS
When I received a call from HPBooks to write this book, I was ecstatic. At the time, I thought it would really be as simple as writing a bunch of magazine articles with a common thread tying them together. I had no idea that I would have to learn to format my writing in a very specific manner. My editor, Michael Lutfy, not only gave me the opportunity, but he also patiently guided me through the unique process of writing a technical book, helping to shape what had become a collection of independent articles into a cohesive, structured manuscript on a difficult subject. He graciously extended deadline after deadline as I struggled to revise and reorganize the material and photos, a process greatly hampered by my limited mobility after shoulder surgery. I thank him for his faith in me.
I also had tremendous help from my brother-in-law, Ian Mowat, who has worked in electronics and with electrical circuitry all his professional life. He is the brother Ive always wanted and the task of writing this book would have been much more difficult without him. From helping me to create diagrams, to proofreading and prodding me to get it done, his support has been invaluable. His expertise has helped me explain how a bunch of invisible electrons move down a conductor, how the process works and how it can go wrong, in laymans terms.
I also have to recognize the assistance from COMP Cams, Fuel Air Spark Technology (F.A.S.T.), FlowTech Headers, Holley, M&H Electric Fabricators, MSD Ignition, Painless Performance, RW Industries, Snap-on Tools, Stewart Warner and YearOne. Each of these companies contributed their technology, knowledge and product(s). Without their help this book would not have been possible.
Finally, my wife and two gearhead sons have been the anchor Ive clung to in the rough weather Ive had to overcome while writing this book. They always asked how things were going, were always very supportive, even when I was in denial about the RIGHT way to write a book.
INTRODUCTION
Writing DIY auto books is a difficult task, since it must present a subject to a diverse group of gearheads, teach them as much as possible of the theory without losing their interest, then illustrate how to do it step by step in terms general enough to be applied to any automotive project. It also must be timely and fun to read. For example, in todays world it is not important to understand how to rebuild a generator. We use alternators and when they wear out they get replaced with a new or remanufactured unit. Therefore, that old generator subject isnt needed anymore.
Wiring a car from scratch is a daunting task for nearly everyone but the most experienced electrical expert. Overall, the task seems complex, but when you break down electrical systems into smaller bits, youll find it isnt all that difficult. I had the opportunity to do three complex projects for this book, and I found the process to be very rewarding, an experience I hope youll have with your own project.
If you purchased this book, then it means you are trying to increase your knowledge and understanding of the electrons running through the maze of wires in your vehicle. Of course, if you are starting from scratch you want to know where and why wires should go in a particular location and how to complete circuits. This book was written as a modern reference book about automotive electrical systems. With the information inside, Im confident you can learn to wire a complete vehicle from scratch, start to finish, or just fix a circuit that isnt behaving properly. It doesnt matter if it is in a hot rod, street rod, muscle car, race car or family sedan, this book will show you how to wire almost any vehicle.
I am assuming that like most readers of HPBooks, you will already have the basic tools needed to work on cars. Any specilized electrical tools, like mulitimeters, volt meters, strippers and crimpers, are covered within the context they are used. The first chapters cover the basics of electricity and define terms like amperes, volts and watts and take you into reading the road maps of electrical circuits and wiring diagrams. They are the foundation you need to build your confidence and knowledge base to a point that you are ready to jump right into a project. From here we jump right into big electrical projects with step-by-step photos and text to walk you through almost any electrical installation you may have in mind for your own vehicle. We wire a Pro Street 1956 Ford pickup from start to finish. We replace every single wire in a 1971 Barracuda, we integrate a new wiring kit into the stock engine management system on an Acura race car and finally, we install two electronic fuel injection systems into two different vehicles. We also do a high-end radio installation for a modern vehicle, plus review the radio installation in the 1956 Ford pickup. We wrap things up with a section on troubleshooting tips that can be used in any kind of vehicle, from grocery getter to race car.
Remember that the car hobby is supposed to be fun, and that even goes for electrical projects. Your investment in time and energy will make you a better mechanic and hot rodder. Perhaps the greatest reward you can receive is the satisfaction from having done the job yourself. Hopefully, this book will help you get there.
Matt Strong
Chapter 1
Basic Auto Electrical Theory
When you are wiring up an EFI system, such as connecting the MAP sensor as shown here, you need to understand basic electricity to know why you do things as well as what to do. Instructions from suppliers are good enough to get you through the installation if you are patient, but understanding what things do will allow you to do a great job and have everything looking as good as it runs.
Electrical theory can be very boring and confusing to some folks, mainly because you cannot see the electrons running through wires, relays, coils or other elements of a vehicle electrical system. For that reason we are not going deep into theory, but we are giving you more than enough to understand electricity in any circuit; car, truck or even your home. In this chapter well cover the principles of voltage, resistance and circuits. Later, when you are working on your own project, they will help you focus upon important details and you will understand why you need to be doing specific things. We are also using examples of fluid circuits to explain how electricity does its job. Take your time reading this chapter and you will find it contains a lot of useful information.
Understanding Electrical Flow
Electricity behaves a lot like a fluid; we say it flows through the wires. It runs from one battery terminal to the other and all the wires between them when called upon, just like the fluid in a hydraulic (liquid) system. The fluid pump is the battery or alternator and the fluid is under pressure. How much pressure depends on the pumps power. The fluid delivers energy to components and makes them work. If you have a large hydraulic ram, you need a large pipe to feed in the power. But for smaller rams a smaller pipe will be fine. To both, though, the same pressure is delivered (usually between 1,000 and 3,000 psi).
