The car wiring harness is one of the most important components of a vehicle’s electrical system that connects all electrical devices such as the powertrain, sensors, lighting and entertainment systems. Whether it’s the engine wiring harness, car radio wiring harness or car stereo wiring harness, they all play a crucial role in transmitting electrical signals. Faults can not only affect vehicle functionality but also potentially create safety hazards.
To help users quickly understand common fault types in car wiring harnesses, the following will explain them from five aspects and provide some basic troubleshooting suggestions.
Wiring Harness Wear
During vehicle operation, wiring harnesses are affected by vibration, friction and temperature changes. If the wiring harness is close to the engine, the edge of the body or rubs against metal parts for a long time, the outer sheath may be damaged. Worn wiring harnesses can easily expose the metal wire cores that lead to short circuits, signal interruptions or current interference.
Common abnormal phenomena include:
- Noise in the audio system – often seen in car audio wiring harnesses
- Flickering headlights/fog lights
- Intermittent fault codes in the vehicle
Solutions: Regularly check wiring harness mounting points, add protective sleeves to the wiring harness and check the contact points with the vehicle frame.
Water Ingress into Car Wiring Harnesses
Many vehicle connectors are located in areas prone to water accumulation such as doors, the bottom of the trunk and under the body. When moisture seeps into these connectors, it can cause corrosion, short circuits or poor contact. The wiring harness particularly for the car stereo is more susceptible to performance degradation due to water ingress.
Common abnormal phenomena include:
- Car head unit malfunction
- Intermittent radio signal – possibly related to the car radio wiring harness
- No image from the reversing camera
- Door malfunction
Solutions: Clean and dry the connectors, apply waterproof sealant and check the sealing of the rubber seals.
Burn or Corroded Car Wiring Harnesses
Short circuits, overloads or improper modifications can all cause partial burnout of the wiring harness. For example, if the owner replaces audio equipment or modifies the amplifier without replacing it with a dedicated car deck wiring harness according to the current requirements, the wiring harness temperature may rise and cause the insulation layer to burn.
Common abnormal phenomena include:
- A burning smell inside the car
- A sudden and complete failure of an electrical system
- Fuses blowing frequently
- The audio system cannot start – mostly involve the car stereo wiring harness
Solutions: Check for overcurrent points, replace the burnt section of the wiring harness and use connectors that meet specifications.
Poor Contact
When the cable is out of order, the most common problem is poor contact. When the automotive connector ages, becomes loose or the pins oxidize, the electrical signal will be intermittently interrupted especially when the vehicle vibrates.
Comprehensive typical examples:
- Sound left and right vocal tract large and small, it is possible car audio wiring harness signal indeterminate.
- Car dashboard lights flash randomly
- Intermittent engine vibration – abnormal sensor signal
- Car center console screen restarts unexpectedly
Solution method: Clean the terminals, re-tighten the pins and replace worn connectors.
Wire Rupture
When the wire bundle rebounds or bends over a long period of time, it is easy to break. For example, the cables attached to the car are the most commonly seen repair items during car wiring harness repair.
Contains common failures:
- Loss of voice and loss of voice
- The car window cannot be rolled up or down.
- The trunk button is unresponsive.
- Reversing radar not working
Solution method: Inspect the location of the break, resolder or replace the broken part of the wiring harness.
How to Reduce Automotive Wiring Harness Failures?
Choosing high-quality automotive connectors and wiring harnesses along with reliable materials and crimping processes can reduce future failures.
Avoid improper modifications especially load upgrades related to car stereo wiring harnesses.
Regularly check the wiring harness fixing status and protective measures.
When there is a breakdown, it is recommended to first contact a professional team for car wiring harness repair.
High-quality Available Automotive Connections Manufacturer
The importance of the car wiring harness and the electrical system of the car is undeniable. From simple car stereo wiring harnesses to the main vehicle wiring harness, every connection is related to the stability of the vehicle’s functions. Wiring harness wear, water ingress, poor contact, burning, and breakage are common problems. Regular inspections, preventing moisture intrusion, using high-quality wiring harnesses and avoiding improper modifications can all effectively reduce the failure rate.
If you are looking for reliable automotive connectors or custom wiring harness solutions for your car, click here to consult the TIANDIAN team. Choosing a professional manufacturer of automotive connections will greatly improve system stability and reduce future maintenance costs.