Self-Diagnostic System: INTERMITTENTS

Most intermittents are caused by poor electrical connections or wiring. Check for poor mating of connector halves, or terminals not fully seated in connector body. Check for corrosion or dirt that may impede terminal contact. Check for damaged connector body that may cause poor mating, terminal contact, or exposure to dirt or moisture. Check for improperly formed or damaged terminals that may cause poor contact and possible corrosion.

Using Connector Test Adapter Kit (J-35616-A), probe terminals to check terminal contact tension, thus avoiding damage to terminals. Using connector test adapter kit will help to avoid contamination and deformation to terminal contact. Contamination is caused by improperly connecting connector halves, missing or damaged connector seal or damage to connector. These would cause terminals to be exposed to dirt or moisture. Contamination at connector leads may cause terminal corrosion. This may lead to open or intermittent open circuits. Deformation is caused by improperly probing the mating side of connector terminal, improper joining of connector halves, or repeated disconnecting and connecting of connector halves. Deformation, usually to female side of connector, may result in poor terminal contact, causing an open circuit or intermittent open circuit.

Check for poor terminal-to-wire connections. To check terminal-to-wire connections, remove terminal from connector and check for poor crimps, poor solder joints, crimping over insulation rather than wire, and corrosion in terminal-to-wire contact area. Check wire insulation for rubbed through areas, causing an intermittent short when bare area touches other wiring or components. Check for broken wiring inside insulation. Broken wiring may lead to false conclusions during a continuity or voltage check. If one or 2 strands of wire are intact, system may not operate properly, yet may show continuity with an ohmmeter.

If a visual inspection does not reveal cause of problem, vehicle may be driven with DVOM connected to suspect circuit. An abnormal reading when problem occurs indicates problem may be within that circuit.