Moisture and Corrosion Inspection - Continued
6. Moisture can also travel to a connector through the inside of a wire. If moisture is found in a connector,
thoroughly check the connector's harness for damage. Also check other connectors that share the harness
for moisture. Repair the connectors or the wiring, as required. Ensure that all of the seals are properly in
place and that the connectors have been reconnected.
The ECM is a sealed unit. If moisture is found in an ECM connector, the ECM is not the source
of the moisture. Do not replace the ECM.
7. If corrosion is evident on the terminals or the connector, use only denatured alcohol to remove the corrosion.
Use a cotton swab or a soft brush to remove the corrosion.
8. If moisture was found in the connectors, run the engine for several minutes and check again for moisture. If
moisture reappears, the moisture is wicking into the connector. Even if the moisture entry path is repaired, it
may be necessary to replace the wires.
Wire Insulation Damage Inspection
Carefully inspect each wire for signs of abrasion, of nicks, and of cuts. Inspect the wires for the following
a. Exposed conductors
b. Wire rubbing against the engine
Wire rubbing against a sharp point
Check all wiring harness fasteners and verify that the harness is properly secured. Also check all of the
fasteners and verify that the harness is not compressed. Pull back the harness sleeves in order to check for a
flattened portion of wire. A fastener that has been over-tightened flattens the harness. This damages the
wires that are inside the harness. Repair or replace damaged wires, as required.
Connector Terminal Inspection
Visually inspect each terminal in the connector. Verify that the terminals are not damaged. Verify that the
terminals are properly aligned in the connector and verify that the terminals are properly located in the connector.
Repair the terminals and/or replace the terminals, as required.
Wire Terminal Connection Pull Test
Ensure that the locking wedge for the connector is installed properly. Terminals cannot be retained inside the
connector if the locking wedge is not installed properly.
2. Conduct an adequate pull test on each wire. Each terminal and each connector should easily withstand 10 lb
(45 N) of tension and each wire should remain in the connector body. This test checks whether the wire was
properly crimped in the terminal and whether the terminal was properly inserted into the connector. Replace
damaged connectors, as required.