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Practical Wiring - Club Level: Design Confirmation Testing

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Design Confirmation Testing

03.59

00:00 - The design confirmation testing process is the one of continuity testing our harness and physically measuring it to make sure that it does match our design documentation.
00:10 Now as we've built our harness in a reasonably logical manner, we are pretty confident at this stage that we are going to have met our design criteria, however we really do want to test that before we install it in the vehicle, as still finding a problem at this stage is going to be easier than when we power it up for the first time in the car.
00:28 Now the process we've gone through building our harness has involved quite a lot of continuity testing already so we do have a leg up on this process and that does give us that little bit of extra confidence that all our pins are going to be in the correct place.
00:41 It is still worth testing your harness completely point to point and by that I mean testing that each pin connects to where you expect it to, just for that extra bit of piece of mind before you power it up for that first time.
00:54 Before we do any continuity testing though we're actually going to physically measure our harness branch sections to ensure that they do match our physical layout document.
01:04 So I'm going to get my tape measure out here.
01:06 We're going to start with our main harness trunk here as it is a reasonably logical starting point.
01:13 Our design documentation calls out a measurement between branches of 350 milllimetres.
01:18 So if we run our tape measure across here, from the edges of those cable ties we are right on that 350 millimetres.
01:27 So we are off to a pretty good start there.
01:29 The rest of the procedure is very much exactly the same.
01:32 You just want to go through and confirm that your harness does measure up and match your design documentation.
01:37 The other part of our design confirmation and testing process is going to be using our multimeter on the continuity setting to test that every pin in our harness is connected to all the other pins that we expect it to be.
01:49 As an example I'm going to start with our ECU one connector here.
01:53 I'll look at number one pin on that connector, a fairly logical starting point.
01:57 Number one pin on ECU one for our Link Fury here is injector channel number four which should be our rear secondary injector on the harness here.
02:06 So I'm gonna get my multimeter probes out and just test the continuity between those two points and make sure it is correct.
02:14 So I can get my multimeter probe installed in pin number one here.
02:17 This is made nice and easy 'cause I've got these good sharp needlepoint probes on my multimeter here.
02:23 And then we're gonna go over to the other end of the loom and find our rear secondary injector plug which is this one here.
02:30 And our signal line is going to be our white because our red is going to be our power supply, so we should see continuity between those two points, which we do, excellent.
02:42 Now as you're doing this you're going to want to mark off that you have tested that connection on your connection document as you're going to work through the harness, I typically start with the interior plugs as they are quite dense and it's an easier place to work from.
02:56 However now that you've tested this particular connection, you don't have to test it from the other direction when you come to testing the connectors on the engine bay side of the vehicle.
03:05 And if you're noting these down as you carry out the process, you will be able to keep track of where you're up to.
03:11 But the rest of the process is very much the same.
03:13 You want to go through and test every pin on your harness and make sure it is making a connection to where you expect it to.
03:21 Now this isn't going to be a complete 100% test of your harness.
03:25 As although you have tested that every pin makes a connection where you expect it to, you haven't tested that it's not making a connection to where you're not expecting it to.
03:35 That would require testing every pin versus every other pin on our harness, and that procedure gets out of control very very quickly and it's not something you're going to be able to undertake on the bench.