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A dirty afternoon to you all! I have a bit of a dilemma, and need some help learning how to repair a damaged wiring harness.
My 2003 Dodge Grand Caravan 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).
Don’t leave out anything you think might be too basic…I have zero experience repairing these things. Thanks for the help.
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I just fixed this on my 2002 town and country van I used part #5017114AA from this website http://www.wholesalemopar.com about $50 including s/h. I got info from here http://forum.chryslerminivan.net. I removed the power steering reservoir so i would have more room and i soldered the wires together with heat shrink on the wires.
I looked around a little and found this link to a You Tube video on how to solder:
A couple of pointers: The wire size in the video can be soldered with the Radio Shack $10.00 iron. Use heat shrink and you can use the side of the iron to shrink the tubing since you probably don’t have a heat shrink gun. If you have several wires in the harness, please stagger the joints so you don’t have a giant wad of wires on each end of the repair. If you are doing this outside in the wind you need a much larger iron and I would recommend a propane torch with soldering tip, just be very careful and practice with the heat settings. You can get one from the home store plumbing section.
Eric has a soldering video (sort of) that is worth viewing also for background info.
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