Electrical Circuit Inspection Procedure

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.

   Fig 1: Checking Open Circuit

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2. Continuity Check Method
   NOTE: When measuring the resistance, lightly shake the wire harness up and down 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 connectors (A) and (C) as shown in Fig 2.

      In Fig 2, the measured resistances of line 1 and 2 are higher than 1 MΩ and below 1 Ω respectively. Specifically, an open circuit is in line 1.

      (Line 2 is normal.) To find the exact broken point, check the sub line of line 1 as described in the next step.

      Fig 2: Measuring Resistance Between Connectors (A) And (C)

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   2. Disconnect connector (B), and measure the resistance between connectors (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).

      Fig 3: Measuring Resistance Between Connectors (C) And (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 voltages of each connector are 5V, 5V and 0V respectively. So, the open circuit is between connectors (C) and (B).

      Fig 4: Measuring Voltage Between Chassis Ground And Terminal 1 Of Each Connectors

      Courtesy of KIA MOTORS AMERICA, INC.

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.

     Fig 5: Checking Short Circuit

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2. Continuity Check Method (with Chassis Ground)
   NOTE: Lightly shake the wire harness up and down, 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 the resistance between connector (A) and Chassis Ground as shown in Fig 6.

      The measured resistances of line 1 and 2 in this example are below 1 Ω and higher than 1 MΩ respectively. Specifically, the short to ground circuit is in line 1. (Line 2 is normal.) To find the 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 KIA MOTORS AMERICA, INC.
   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).

      Fig 7: Measuring Resistance Between Connector (B1) And Chassis Ground

      Courtesy of KIA MOTORS AMERICA, INC.

This test checks for voltage drop along a wire or through a connection of a 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 (50mV in 5V circuits), may indicate a problem. Check the circuit for loose or dirty connections.
   Fig 8: Testing Voltage Drop

   Courtesy of KIA MOTORS AMERICA, INC.