B–28 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Good Example: Bad Example: (Wire insulation is Stripped at a Slant) (Wire Lead is Cut) (Insulation Remains on the Lead) Wire Harness Outside Diameter Insulation Calipers Nominal Size of the Wire Wire Lead Diameter Calipers Twist Evenly NOTICE: Take care not to damage the wire when stripping the wire harness lead. After finishing the operation, visually inspect the wire. If there is any damage, perform the operation again. HINT: If the wire size is not known, start with largest stripper hole and work down until a clean strip of the insulation is removed without nicking or cutting the wire lead. 4. Select Correct Size of Sleeve from the Supply Parts. (a) Measure the diameter of wire by using the measuring device as following: ● When size is based on the outside diameter of the wire harness Measure the outside diameter of the wire harness by placing a measuring device, such as a micrometer or Vernier Caliper, across the diameter of the insulation on the lead and taking a reading. ● When size is based on the nominal size of the wire lead. Measure the diameter of the wire lead by placing a measuring device, such as a micrometer or Vernier Caliper, across the diameter of the wire lead and taking a reading. HINT: To calculate the "nominal size" of wire Nominal size= 3.14 x (Diameter of wire lead)² 4 Wire Harness Repair Manual (RM1022E) 38