Inspection of the Electrical Component

p3 mm 54.01
  1. Park the vehicle, apply the parking brakes, and shut down the engine. Chock the tires.
  2. Disconnect the batteries.
  3. Inspect the condition of the electrical component. Check for signs of excess dirt/debris build up on or around component. If exterior cleaning is needed for a thorough inspection, clean exterior debris from the component using a dry method such as a vacuum cleaner or using an electrical contact cleaner such as CRC QD® Electronic Cleaner.
  4. Check all mounting points for loose, broken, or missing parts. Component must be securely mounted. All loose, broken, or missing parts must be repaired to maintain proper component function.
  5. Inspect the component protective cover for proper fit and function. Inspect cover for cracks, broken mounting, missing sealing surfaces, warped or bulged surfaces. The cover must prevent moisture and debris from entering the components protected area. Missing, leaking, or damaged covers will result in moisture and debris entering the component and will result in component failure. When it is determined that a cover has not properly prevented moisture and debris from entering the component, the entire component must be replaced.
  6. Inspect the component exterior for signs of thermal distortion, warping, bulging, discoloration, amperage related heating, color variance or shading across component which could be a sign of internal failure requiring replacement of the component. The root source causing conditions of high heat, excess amperage, and/or circuit overload component failures must be diagnosed and repaired prior to replacing the component.
  7. Inspect component housing sub-assembly clips and fasteners for correct fit and location and that component sub-assembly housing seams are tight and secure. Missing, leaking, or damaged component housings must be replaced.
  8. Check main power cable connections for a clean and secure fit. Connections should be free of corrosion, dirt and moisture. Connections should not have signs of thermal distortion, warping, discoloration, high amperage heating or discoloring. If needed, disconnect cables, scrub and clean as needed using a nylon brush. Clean debris with vacuum or electrical contact cleaner such as CRC QD® Electronic Cleaner, inspect terminals and mating contact terminal plating. If the terminal plating exhibits signs of unrecoverable corrosion, the component and terminal will need replaced. Indications of unrecoverable corrosion on terminal plating are:

    • Heavy staining that cannot be cleaned off with nylon brush or contact cleaner;

    • erosion and pitting on terminal plating causing uneven surfaces; or

    • discoloration caused by outer layer of plating being removed by corrosion or wear exposing the under layer material of terminal.

  9. Check all electrical connectors for correct fit and that the connector locking tabs are in place and will hold the connector firmly into the component. Inspect connector terminals for signs of corrosion, thermal distortion, warping, discoloration, high amperage heating or discoloring. If needed, remove connectors and terminals, scrub and clean as needed using a nylon brush. Clean debris with vacuum or electrical contact cleaner such as CRC QD® Electronic Cleaner, inspect terminals and mating contact terminal plating. If the terminal plating exhibits signs of unrecoverable corrosion, the component and terminal will need to be replaced.
  10. Inspect sealed harness connectors for presence of connector housing seals and connector pin seals designed to keep moisture and debris from entering the connector and component. Missing, leaking, or damaged seals will result in moisture and debris entering the connection and the component and will result in component failure. When it is determined that connector seals have not properly prevented moisture and debris from entering the component, the entire component must be replaced.
  11. Inspect component harnesses for secured routing that prevents excess harness movement and prevents the harness from pulling too tight on the connector. Inspect harnesses for signs of rubbing or chafing that could result in wire circuit damage. Damaged wiring and/or damage to harness protective wrap must be repaired and harness must be wrapped and secured to prevent further damage. When possible, harness should be routed with drip loop.
  12. Inspect fuses and relays for correct fit, and that the terminals hold the fuses and relays firmly in place. Inspect fuses and relays for signs of corrosion, thermal distortion, warping, discoloration, and high amperage heating or discoloring. If loose or corroded, remove, inspect, clean, and replace as needed.
  13. Connect the batteries.
Note:
Parent topic: Electrical, Instruments, and Controls
Document Number: 0000116533
Manual Publication Date: 2024-05-15
Topic Publication Date: 2024-11-22