Electrical Connections or Wiring

Electrical connections and wiring cause most intermittent conditions. Determine which circuit is suspected of having an intermittent condition. This may be indicated by DTCs with a fault not present. Check the suspect circuit for the following conditions:

• Any connectors that are poorly mated.
• Any terminals that are not fully seated in the connector.
• Any terminals that are not properly formed or damaged.
• A poor male to female connection. Checking for proper terminal retention requires the use of Terminal Repair Kit (J 38125-B), or equivalent.
• Any poor terminal-to-wire connections. Checking for poor terminal-to-wire connections requires removing the wire/terminal from the connector body.
• Any wires that are broken inside the insulation.
• A pierced or damaged insulation that allows water or moisture to enter the wiring. The conductor can corrode inside the insulation with little visible evidence. Look for swollen and stiff sections of wire in suspect circuit.

Check for intermittents by performing applicable procedure from the following list:

• Move related connectors and wiring while monitoring appropriate scan tool data.
• Move related connectors and wiring with component commanded ON and OFF, using the scan tool. Observe component operation.
• With engine running, move related connectors and wiring while monitoring engine operation.

Verify whether the harness or connector movement affects any of the following systems:

• Data displayed.
• Component or system operation.
• Engine operation.

Repair as necessary.