It Definitely Matters

It Definitely Matters

Why does wire size/gauge, material composition (Resistance wire) or strand count matter. It affects the signal integrity. Let’s start with a recent customers dilemma.

Customer Statement:We were notified that the wire harness they had was flagging an Oxygen Sensor fault. The assembly was previously repaired. The harness assembly was shipped in under our Remove and Repair (R & R) program. To the naked eye, everything looked normal. During our “Hidden Damage” inspection phase, quality control recognized a discrepancy in the stranding and material composition/alloy content (Copper). This discrepancy caused the ECM to recognize a higher-than-normal value and turned on the Check Engine light.

The Fix: We replaced the wire with the correct OEM specifications. System checks okay!What was the impact of this discrepancy? The wire used during repair did not comply with the alloy (Material) content required by the OEM. Essentially, it is a resistance wire (See images). A good example of a resistance wire is your heated seats.
Resistance Wire Spooled for productionHeated SeatConnector in question

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