Failure Analysis: Damaged Wiring Harness Connectors
The common factors that lead to damage to the wiring harness connectors are product quality problems, and the second factor is the assembly factor. Most of the assembly factors are caused by violent operations.
Fault phenomenon: A prototype of the Wuling Zhiguang extended car produced by SAIC-GM-Wuling Automobile Co., Ltd. is equipped with a 1.2L engine and has a mileage of more than 28,000 km. The test personnel found that the engine fault light was always on during the daily inspection of the vehicle. .
Inspection result: After clearing the fault code with the diagnostic instrument X431, it was observed for two days, and it was found that the fault reappeared. After reading the fault code P0075, it was found that the circuit of the engine intake valve was faulty. After inspection, the test personnel found that the engine wiring harness was connected to the intake VVT ​​valve and the intake air. The VVT ​​valve cannot be docked reliably.
Cause analysis: The faulty part was disassembled from the prototype and returned to the wiring harness engineer. By comparing the faulty part and the normal part, it was found that: before the docking, the secondary lock of the normal part was in a non-locking state, while the faulty part was in a locked state, as shown in the figure 5. It is difficult to lock the secondary lock in the non-assembled state, and the violent operation causes the secondary lock to lock before docking.
Corrective measures: Mark the connectors with secondary locks in the automobile assembly process and attach disassembly and assembly instructions.