122 RENR5042-02 Troubleshooting Section Expected Result: The harness wiring, connectors, and seals are in good condition. There is no evidence of moisture in the connectors. Results: OK – The harness wiring, connectors, and seals are in good condition. Proceed to Test Step 2. Not OK A problem has been found with the harness or the connectors. Repair: Repair the connectors or the wiring, as required. Ensure that all of the seals are properly in place. Ensure that the connectors have been reattached. If corrosion is evident on the pins, sockets or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion.
g01131165 Illustration 49 Seal for ECM connector (typical example) C. Disconnect the suspect connector and inspect the connector seal. Ensure that the seals are in good condition. If necessary, replace the connector. 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. D. Thoroughly inspect the connectors for evidence of moisture entry. Note: It is normal to see some minor seal abrasion on connector seals. Minor seal abrasion will not allow the entry of moisture.
Verify that the repair eliminates the problem. STOP. If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and the source of the moisture entry must be repaired. If the source of the moisture entry is not repaired, the problem will recur. Simply drying the connector will not fix the problem. Check the following items for the possible moisture entry path: Test Step 2. Check the Wires for Damage to the Insulation A. Carefully inspect each wire for signs of abrasion, of nicks, and of cuts. Inspect the wires for the following conditions:
Missing seals Exposed insulation Improperly installed seals Rubbing of a wire against the engine Nicks in exposed insulation Rubbing of a wire against a sharp point Improperly mated connectors B. Check all of the wiring harness fasteners in order to verify that the harness is properly secured. Also check all of the fasteners in order to 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 overtightened flattens the harness. This damages the wires that are inside the harness. 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. Note: 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.