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Help needed repairing wiring harness
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Saxon
New User
Nov 1, 2012, 1:49 PM
Post #1 of 9
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Help needed repairing wiring harness
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Good afternoon! I'm new to the forum and have a bit of a dilemma. I have a 2003 Dodge Grand Caravan that threw me code P0206 and P0306 about a bad injector on cylinder 6. I replaced the injector, but got a tip from a Dodge tech to check the fuel rail wiring harness for melted wire casings (which is, I gather, a common problem for this generation of Caravan). Sure enough, the heat resistant sleeve had broken down, and the exhaust manifold melted all the wire casings off thus exposing copper and causing shorts. (It looks similar to this: http://s3.amazonaws.com/..._023225_dsc01601.jpg).
A new wiring harness is about $285 from the dealer (a bit cheaper online). I've heard there is a repair kit, and I think the connector I do have might still be ok. I'd much rather be able to repair the harness than fork out almost $300, but have never done any wiring repair before. How would I go about properly repairing the wiring harness? It looks like a 10-pin connector (you can see it in the photo above).
Sorry for my complete lack of experience in the auto electrical world; but everyone's gotta start somewhere. I really appreciate the help.
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Saxon
New User
Nov 1, 2012, 2:13 PM
Post #3 of 9
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Re: Help needed repairing wiring harness
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Yeah, that will definitely be the limiting factor for me, but I figure I may as well at least try before submitting the $300 bill.
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Hammer Time
Ultimate Carjunky
/ Moderator
Nov 1, 2012, 2:50 PM
Post #4 of 9
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Re: Help needed repairing wiring harness
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That's not the way to look at this. Making a mistake here can cost you some serious money. You can easily fry one or more computers or even melt the rest of the harness. You can also create intermittent problems that you will be chasing for years. This isn't a "trial and error" type job. You only get one shot to do it right.
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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nickwarner
Veteran
/ Moderator
Nov 1, 2012, 8:24 PM
Post #5 of 9
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Re: Help needed repairing wiring harness
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HT is right about this. If it was a little thing like a taillight harness or something that would be different. I see you have the same username an post on ericthecarguy too. You got a few posts there. Here's my professional opinion.
You have no knowledge of exactly what is occurring electrically with high-impedence piezo injectors and the correlation between them and your PCM. Its not like a light switch. You could try to put in a pigtail, but you cannot just use a crimp connector or you will never have this run right again. If you get a wire backwards when you do it you will be out a brand new PCM that must be programmed to your VIN at a dealership to even get it to start plus still have to replace the $300 harness. You know nothing about soldering nor do you own the proper equipment to solder solid state electronic components. This needs a fine rosin core solder and a quality heat shrink tube applied over it. If there is any inperfection in the connection the van will run horrible and will continue to spit out that code. If you want to learn how to solder, go ahead and learn. But not on this. Way too much at stake. Get a roll of wire, a soldering gun and solder and practice with it. If you still want to try to save the injector harness, unplug and remove it.Get the replacement pigtails and go to an electronics repair shop or (even cheaper) the electronics department of your local technical college and ask them to replace the connectors for you. The tech school would probably let you watch them do it and answer a question or two if you don't break their concentration and become a nuisance.
The end result of that would of course save you the money you are trying to save, but the guaranteed fix is going to be the new harness that hasn't been through the bake cycle. Its your car, its your money, and this is free advice based on the knowledge and experience we here use professionally to put food on the table. No backyard shadetree guys here.
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Hammer Time
Ultimate Carjunky
/ Moderator
Nov 2, 2012, 3:03 AM
Post #6 of 9
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Re: Help needed repairing wiring harness
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Also, it only takes a momentary contact with the wrong wires to toast a computer.
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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Saxon
New User
Nov 2, 2012, 11:46 AM
Post #7 of 9
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Re: Help needed repairing wiring harness
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I appreciate your and HT's opinion on the matter; much of what I've learned about auto repair has been from tapping into the vast knowledge of the professionals on sites like this (my experience is that its the good, honest pros who take the time to post on sites like this). In fact, I'd have never noticed the fried harness if a Dodge tech (on a completely unrelated question) hadn't mentioned that it's a common problem he's see dozens of times, and he'd seen some shops troubleshoot the issue for months without figuring it out. He figured he'd mention it before I blew through a bunch more injectors and fried the PCM.
I was planning to just replace the harness all together for the very reasons you cited: the new one hasn't been sizzled for 10 solid years, and I lack any decent electrical repair experience. I just figured if I could reasonably repair it properly myself, I may as well save the money.
In the same van there are a couple of accessory outlets that need a bit of help, that's where I was planning to cut my teeth in soldering wires and electrical repair, and based on what you've both said, that's probably where I'll start. Thanks again for the input.
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Tom Greenleaf
Ultimate Carjunky
/ Moderator
Nov 2, 2012, 11:59 AM
Post #8 of 9
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Re: Help needed repairing wiring harness
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Stinks that the OE harness is that much but would be the best and safest repair not wrecking something else with even a minor mistake in splicing all those up if no decent well rated wire is easily available.
Wire isn't all the same nor the insulation. Somewhat on topic but go grab the cord to a toaster (real home toaster) and compare that to the feel of just a table lamp's cord. Wild difference in properties.
Not much beat doing it right,
T
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nickwarner
Veteran
/ Moderator
Nov 2, 2012, 4:43 PM
Post #9 of 9
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Re: Help needed repairing wiring harness
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An excellent idea to learn the electrical on those outlets. I know eric has several videos about troubleshooting electrical and voltage drop testing, and a 12v test light and multimeter can be had for cheap. For soldering I think you would want to get a gun made by Weller. Can be had pretty much anywhere that sells them and good quality without wrecking the wallet. Radio Shack sells a very thin rosin core solder that is awesome and a roll of it lasts me years even though I'm working on stuff every day. We're all for people learning new things and saving money. Thats what this site is about, thats why Eric posts the videos he makes.
It might be worth looking into your local tech school to see if they have a small night course about these basics, or a small auto maintenance course. Fees are usually reasonable and the classes are geared towards novices trying to learn more about their vehicles and perform their own basic repairs.
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