WIRING HARNESS AND WIRING HARNESS CONNECTORS INSPECTION CONTINUED
3. Inspect the connector seal for the following:
loose fit on connector body
4. Intermittent electrical problems are often caused by poor connections. Inspect pin and mating terminal for the
bent or damaged pin
loose or wobbly fit in connector body
elongation or expansion
Verify terminals are properly anchored in connector body by gently pulling on wire at rear of connector
body. Replace affected wiring harness if wire or terminal moves free from connector body.
5. Perform each of the following inspections to identify faults with the suspected circuit, harness, and connection.
Inspect Wiring Harness Connectors for Moisture and Corrosion
1. Check that routing of suspected wiring harness does not cause excess tension on wires at each connector.
Excessive wire tension will deform connector seal bore.
2. Ensure sealing plugs are in place. If any plugs are missing, replace affected wiring harness. Ensure plugs are
inserted correctly into connector.
It is normal to see minor seal abrasion on connector seals. Minor seal abrasion will not
allow entry of moisture.
If moisture or corrosion is evident in connector, source of moisture entry must be found
and source of moisture entry must be repaired. If source of moisture entry is not repaired,
fault will recur.
Moisture can also travel to a connector through the inside of a wire. If moisture is found in
a connector, thoroughly check wiring harness for damage.
3. Disconnect suspect wiring harness connector and inspect connector seal. Ensure seal is in good condition.
4. Inspect connector body for evidence of moisture entry. Ensure seal is in good condition.
Inspect the following items for possible moisture entry path:
Loose or stretched seals
Incorrectly installed seals
Cracked, warped, or damaged connector body
Broken, missing, warped, or damaged locking tab on connector body
Improperly mated connectors