ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED
ELECTRICAL CONNECTOR INSPECTION (POWERTRAIN) - CONTINUED
Expected Result. Wires are free of abrasion, nicks, or cuts and harness is properly clamped.
If wires are free of abrasion, nicks, or cuts and the harness is properly clamped, go to step 6.
If a problem exists with wiring, repair wires or replace the wires, as required.
Check Connectors for Moisture or Corrosion.
Ensure connector seals and white sealing plugs are in place. If any seals or plugs are missing, replace seal or plug.
If necessary, replace connector.
Check all wiring harnesses in order to verify harness does not make a sharp bend out of a connector. This will
deform connector seal and create a path for the entrance of moisture.
N OT E
It is normal to see some minor seal abrasion on the ECM connector seals. Minor seal abrasion will not allow
the entry of moisture.
Thoroughly inspect ECM connectors for evidence of moisture entry. If moisture or corrosion is evident in the con-
nector, the source of moisture entry must be found and repaired. If source of the moisture entry is not repaired, the
problem will recur. Simply drying connector will not fix the problem. Likely paths for entrance of moisture are
from missing seals, improperly installed seals, nicks in exposed insulation, and improperly mated connectors.
C AU T I O N
Moisture can also travel from one connector through the inside of a wire to ECM connector. If mois-
ture is found in ECM connector, thoroughly check all connectors and wires on the harness that connect
to ECM. ECM is not the source of moisture. Do not replace an ECM if moisture is found in either ECM
If corrosion is evident on contacts or connector, us only denatured alcohol to remove corrosion. Use a
cotton swab or a soft brush to remove corrosion. Do not use cleaners that contain trichloro-ethylene
because trichloro-ethylene may damage connector.
Expected Result. All connectors should be completely coupled and all seals should be completely inserted. Har-
ness and wiring should be free of corrosion, moisture, abrasion or pinch points.
If all connectors are completely coupled and all seals are completely inserted, and harness and wiring are
free of corrosion, moisture, abrasions, or pinch points, go to step 7.
If a problem exists with connector, wiring, or wiring harness, moisture is present. Repair connectors or
wiring and/or replace connectors or wiring. Ensure all seals are properly in place and ensure connectors
are completely coupled. Verify repair eliminates problem by operating machine for several minutes and by
checking again for moisture.
Inspect Connector Contacts.
Verify contacts are not damaged. Verify contacts are properly aligned in connector and verify contacts are properly
located in connector.
Expected Result. Contacts are properly aligned and contacts appear undamaged.
If contacts are properly aligned and contacts appear undamaged, go to step 8.
If a problem exists with connector contacts, repair contacts and wiring and/or replace the contacts and wir-