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This article introduces several common failure modes of automotive engine wiring harnesses. The common failure causes are analyzed and discussed to help the optimization and improvement of automotive engine wiring harnesses.
Failure phenomenon: vehicles driving frequently speedometer indicates zero speed, odometer indicates small mileage, intermittently return to normal on their own.
Cause: A broken wiring harness can lead to a common automotive failure mode of line breakage. The reasons for a broken wiring harness can be simply listed as the following 3 points: ① the branch design of the wiring harness is too short; ② the manufacturing of the wiring harness is not standardized; ③ twisting the wiring harness during assembly.
Failure phenomenon: engine wiring harness connected to the crankshaft position sensor branch and clutch sub-pump mounting support interference, and found that the wiring harness branch here has wear
Cause: An important reason for the engine wiring harness to wear is interference with surrounding parts. engine wiring harness is arranged in a wide area and is a deformed part, compared to other engine parts, the wiring harness has a high probability of interference with surrounding parts.
There are many reasons for the harness and peripheral parts interference, such as harness branch design is too long resulting in excessive harness margin, and peripheral parts interference; assembly process does not meet the design requirements; unreasonable layout, insufficient space, or lack of fixed points, and peripheral parts are too close to the distance, resulting in interference.
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Fault phenomenon: the engine fault light is always on
Cause: The common factor leading to damage to the wiring harness plug connector is the quality of the product, the second factor is the assembly factors, assembly factors are mostly due to violent operations.
Fault phenomenon: the engine can not start. Testers re-connection of the rail pressure regulator valve sensor plug, the engine can start normally, but after the engine works normally, the fault again.
Cause: harness assembly plug poor is the engine wiring harness a common failure mode, prompting this failure mode can be simply divided into the following three causes: ① sheath production and manufacturing quality problems; ② plating set unreasonable, terminal oxidation too fast; ③ human factors in the assembly process to deform the plug terminals.
Corroding, cracking, and crumbling can occur as a result of prolonged use. A harness can bend when temperatures suddenly go from very hot to very cold, for example. Over time, normal wear can stiffen the harness, causing areas to become softer and break off. Degradation can occur when extreme weather conditions are present.
In the absence of proper maintenance or adjustment, user error can cause problems, including incorrect wire layout, poor connection to the harness chassis, or inexact measurements that prevent the entire wiring harness from fitting properly.
A lower speed is causing the engine to shut down.
Problems starting the vehicle with the battery wiring harness.
A battery wire harness that corrodes the battery terminal.
There are problems with the lights and other electrical components.
A dead battery or a rapid loss of charge can be a sign of a faulty wiring harness. Similarly, if your car suddenly starts or idles down unexpectedly, or if it stutters or lurches while driving, it is also a sign of a damaged wiring harness.
In an engine wiring harness, wires, cables, connectors, and terminals are arranged to control the electrical system of the vehicle. The engine wire harness relays electrical power and controls information to other components, such as alternators.
Make sure the old and new connectors are the same.
You need to strip the ends of the wires to replace the wiring harness.
The ends of the wires need to be turned.
The wires should be crimped with an insulated connector.
The Insulated Connector needs to be melted to the Wiring…
Make sure the wire is attached to the electrical tape.
We are an engine wiring harness supplier, please feel free to contact us if you need them.
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