Wire Harness Inspection Procedure

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

ELECTRICAL CIRCUIT INSPECTION PROCEDURE

CHECK OPEN CIRCUIT

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.

Fig 1: Checking Voltage And Continuity
Courtesy of HYUNDAI MOTOR CO.
Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from side to side.

Specification (Resistance)

1ohm or less --> Normal Circuit

1Mohm 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 1Mohm and below 1 ohm 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.
  
  Fig 2: Measuring Resistance Between Connectors (A) And (C)
  Courtesy of HYUNDAI MOTOR CO.
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 1^Mohm and the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Fig 3: Measuring Resistance Between Connectors (C) And (B1) And Between (B2) And (A)
Courtesy of HYUNDAI MOTOR CO.
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).
Fig 4: Measuring Voltage Between Chassis Ground And Terminal 1 Of Each Connectors (A), (B) And (C)
Courtesy of HYUNDAI MOTOR CO.

CHECK SHORT CIRCUIT

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 below Step 5 (Continuity Check Method with Chassis Ground) as shown below.

Fig 5: Checking Continuity With Chassis Ground
Courtesy of HYUNDAI MOTOR CO.
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)

1ohm or less --> Short to Ground Circuit

1Mohm 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 1 ohm and higher than 1Mohm 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.
  
  Fig 6: Measuring Resistance Between Connector (A) And Chassis Ground
  Courtesy of HYUNDAI MOTOR CO.
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 1ohm or less. The short to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Fig 7: Measuring Resistance Between Connector (A), (B1) And Chassis Ground And Between (B1) And Chassis Ground
Courtesy of HYUNDAI MOTOR CO.