Wire Harness Inspection Procedure

1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly.
2. Check whether the wire harness is twisted, pulled or loosened.
3. Check whether the temperature of the wire harness is abnormally high.
4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part.
5. Check the connection between the wire harness and any installed part.
6. If the covering of wire harness is damaged; secure, repair or replace the harness.

   Electrical Circuit Inspection Procedure 

• Check Open Circuit

1. Procedures for Open Circuit
   • Continuity Check
   • Voltage Check

   If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step  2 (Continuity Check Method) or Step  3 (Voltage Check Method) as shown below.

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2. Continuity Check Method
   NOTE:

   • When measuring for resistance, lightly shake the wire harness above and below or from side to side.

   Specification (Resistance) 

   1Ω or less → Normal Circuit

   1MΩ or Higher → Open Circuit

   1. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as shown in [FIG. 2].

      In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1MΩ and below 1Ω respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point, check sub line of line 1 as described in next step.

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   2. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and (A) as shown in [FIG. 3].

      In this case the measured resistance between connector (C) and (B1) is higher than 1MΩ and the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).

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3. Voltage Check Method
   1. With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each connectors (A), (B) and (C) as shown in [FIG. 4].

   The measured voltage of each connector is 5V, 5V and 0V respectively. So the open circuit is between connector (C) and (B).

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Check Short Circuit 

1. Test Method for Short to Ground Circuit
   • Continuity Check with Chassis Ground

   If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step  2 (Continuity Check Method with Chassis Ground) as shown below.

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2. Continuity Check Method (with Chassis Ground).
   NOTE:

   • Lightly shake the wire harness above and below, or from side to side when measuring the resistance.

   Specification (Resistance) 

   1Ω or less → Short to Ground Circuit

   1MΩ or Higher → Normal Circuit

   1. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as shown in [FIG. 6].

      The measured resistance of line 1 and 2 in this example is below 1Ω and higher than 1MΩ respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line of line 1 as described in the following step.

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   2. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis ground as shown in [FIG. 7].

      The measured resistance between connector (B1) and chassis ground is 1Ω or less. The short to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).

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   Testing For Voltage Drop 

   This test checks for voltage drop along a wire, or through a connection or switch.

   1. Connect the positive lead of a voltmeter to the end of the wire (or to the side of the connector or switch) closest to the battery.
   2. Connect the negative lead to the other end of the wire. (or the other side of the connector or switch)
   3. Operate the circuit.
   4. The voltmeter will show the difference in voltage between the two points. A difference, or drop of more than 0.1 volts (50 mV in 5V circuits), may indicate a problem. Check the circuit for loose or dirty connections.

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