Checking For Intermittents / Preliminary Checks

INTERMITTENTS/HISTORY

CODES/POOR CONNECTIONS
History codes are those indicating that the Sensing & Diagnostics Module (SDM) has previously detected a fault which has since disappeared.

Most intermittents are caused by faulty electrical connections or wiring. Some items to check are:
- Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
- Dirt or corrosion on the terminals. The terminals must be clean and free of any foreign material which could impede proper terminal contact.
- Improperly formed or damaged terminals. All connector terminals in problem circuits should be checked carefully to ensure good contact tension. Use a corresponding mating terminal from (Saturn Tool) SA 9206Z connector test adapter kit to check for proper tension.

NOTE: Connector test adapter kit (Saturn Tool) SA 92O6Z must be used whenever a diagnostic procedure requests checking or probing a terminal. This will ensure that no damage to the terminal will occur.

- Poor terminal-to-wire connection. Checking this requires removing the terminal from the connector. Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, corrosion in the wire to terminal contact area, etc.
- Wire insulation which is rubbed through, causing an intermittent short as the bare area touches other wiring or parts of the vehicle.
- Wiring broken inside the insulation. This condition would cause a resistance to show continuity, but if only 1 or 2 strands of wire are intact, resistance would be too high.

To avoid any of the above problems when making wiring or terminal repairs, always follow proper procedures for wiring and terminal repair.

Terminal Contact Points:

CHECKING TERMINAL CONTACT
When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component.

Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation.

Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination leads to terminal corrosion, causing an open circuit or intermittently open circuit.

Inspect the connector halves for contamination. Contamination will result in a white or green build.up within the connector body or between terminals, causing high terminal resistance, intermittent connection or an open circuit. A connector that shows signs of contamination should be replaced in its entirety; terminals, seals and connector body.

NOTE: Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, causing an open or intermittently open circuit.

NOTE: After intermittent problem has been repaired, clear SIR Codes and repeat the SIR diagnostic system check.