W/Harness Inspection

Terminal and Connector Inspection

1. Electrical systems consist of a lot of harness and connectors, poor connection of terminals can cause various problems and damage of component.
2. Perform checking procedure as follows.
(1) Check damage of harness and terminals : Check terminals for contact resistance, corrosion and deformation.
(2) Check connecting condition of ECM and component connector : Check terminal separation, damage of locking device and connecting condition between terminal and wiring.

NOTE: Disconnect the pin which requires checking at male connector and insert it to the terminal at female connector for checking connecting condition. (after checking, reconnect the pin at correct position.)




3. Has a problem been found ?






Signal Circuit Inspection

1. Check CAN BUS resistance in Data Link Connector
(1) Ignition "OFF".
(2) Measure the resistance between terminals 3 and 11 of data link connector (Test 1)
(3) Disconnect PCM connector.
(4) Measure the resistance between terminals 3 and 11 of data link connector (Test 2)

Specification : PCM and ESC connected : 60 ± 3 ohms (Test 1)
PCM and ESC disconnected : 120 ± 3 ohms (Test 2)





(5) Is CAN BUS resistance within the specification ?





2. Check short to ground in CAN BUS
(1) Ignition "OFF"
(2) Disconnect PCM and ESC connector.
(3) Check continuity between DLC terminal 3 and chassis ground. (CAN HIGH line)
(4) Check continuity between DLC terminal 11 and chassis ground. (CAN LOW line)

Specification : Discontinuity (Infinite ohms)





(5) Is measured resistance within the specification ?





3. Check short to battery in CAN BUS
(1) Ignition "OFF"
(2) Disconnect PCM and ESC connector.
(3) Ignition "ON"
(4) Measure the voltage of DLC terminal 3. (CAN HIGH line)
(5) Measure the voltage of DLC terminal 11. (CAN LOW line)

Specification : 0.0V ~ 0.1V





(6) Is measured resistance within the specification with both connector disconnected ?





4. Check CAN BUS continuity
(1) Ignition "OFF".
(2) Disconnect PCM and ESC connector.
(3) Check continuity in CAN HIGH line. (CAN HIGH : PCM connector terminal 41, ESC connector terminal 35, Data link connector (DLC) terminal 3)
(4) Check continuity CAN LOW line. (CAN LOW : PCM connector terminal 42, ESC connector terminal 14, Data link connector (DLC) terminal 11)

Specification : Continuity (below 1.0 ohms)





(5) Is the measured resistance within the specification ?