Wiring Harness Service

Wiring Harness Service
The control module harness electrically connects the control module to the various solenoids, switches, and sensors in the vehicle engine room and passenger compartment.

Replace the wire harnesses with the proper part number replacement. When splicing signal wires into a harness, use the wiring that has high temperature insulation.

Consider the low amperage and voltage levels utilized in the Powertrain Control systems. Make the best possible bond at all splices. Use rosin-core solder in these areas.

Molded-on connectors require complete replacement of the connector. Splice a new connector into the harness. Replacement connectors and terminals are listed in Group 8.965 in the Standard Parts Catalog.

In order to prevent shorting between opposite terminals, use care when probing a connector and when replacing terminals. Damage to the components could result.

Always use jumper wires between connectors for circuit checking. Never probe through the Weather-Pack seals.

Use the tachometer adapter J 35812, or the equivalent, which provides a convenient connection to the tachometer lead. The connector test adapter kit J 35616, or the equivalent, contains an assortment of flexible connectors used in order to probe the terminals during the diagnosis. The fuse remover and the test tool BT-8616, or the equivalent, is used for removing a fuse and to adapt the fuse holder to a meter for diagnosis.

Open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor or in the wiring harness may temporarily correct the open circuit. Oxidized or loose connections may cause intermittent problems.

Be certain the type of connector and terminal before making any connector or terminal repair. Weather-Pack and Com-Pack III terminals look similar, but are serviced differently.