Wire Maintenance and Repair
FIGURE 36-62
Wiring harness shorted to ground.

Wires are generally trouble free and long lasting. But they can be damaged. Generally speaking, any issues with wiring are more likely to be with the terminals than with the wires themselves. Terminals can corrode, lose their tension, or push back up inside the connector, leading to poor connections and voltage drops. If you suspect a problem with a wire, first inspect the ends. If no problems are found, look for mechanical damage to the wire or wiring harness itself Figure 36-62. When a wire is damaged, it is usually due to one of several conditions. One possibility is that the wire has been physically broken, such as a wire that was not disconnected when removing a major component such as the engine or transmission. Another issue is when a wire gets pinched between components such as between the engine and the transaxle when replacing a clutch. The pinched wire can cause either a short circuit or an open circuit. Wires can also be misrouted so that they lay on a hot surface such as the exhaust manifold, which melts the insulation and causes the wires to short. In all of these cases, the problem can typically be spotted visually. One problem that may be harder to spot is if a circuit shorts out and melts one or more wires together within a harness. In this case, you may have to open up the wiring harness and inspect the wires. Next, we will cover how to repair wires, terminals, and connectors.