1. When replacing wires in an automotive wire harness, improper wire selection (e.g., using wires that are too thin) fails to meet specified requirements. This causes a significant voltage drop and subsequent overheating when high currents pass through, gradually aging and damaging the wire insulation;
Carelessness during battery installation, such as connecting the positive and negative terminals in reverse, internal short circuits in the alternator, damage to insulating washers and sleeves, or reversing the alternator's field and ground wires, can all lead to the burning of the wire harness;
Automotive wire harnesses are often secured using thin metal clips with sharp, knife-like edges and no surface insulation. Due to prolonged vibration and bumping during vehicle operation, the power harness is inevitably worn or cut, causing it to ground and resulting in the burning of the harness;
When temporarily connecting electrical equipment to the wire harness, failing to identify the correct inlet and outlet of the fuse leads to the arbitrary tapping of power lines. Additionally, if a blown fuse is not replaced with one of the exact same specification, or if a thick copper wire is used as a substitute, the protective function is lost, ultimately causing the harness to burn out;
The two terminals of an ammeter often use plastic insulating sleeves. Since plastic has poor heat dissipation, these sleeves must withstand both electrical current and mechanical vibration. If the ammeter wiring is loose or has poor contact, the temperature will rise, melting the plastic and causing a ground fault, which leads to the burning of the wire harness;
Loose terminal connections cause significant voltage drops and overheating. Over time, this can damage the insulating washers, leading to ground short circuits. It is crucial to ensure secure connections at the terminals behind the ammeter and other gauges. Furthermore, the connecting screws for wires fixed to the chassis junction board should not be excessively long, as they may touch the chassis and cause the wire harness to burn out.
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