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Identify a wiring harness from an approved piece of equipment, such as a vehicle, plane, or training/simulator station. Take a well-lit photo of the wiring harness.Be sure to capture all ends of the wiring harness (it may run point to point or it may include several breakouts).
Conduct a brief visual inspection of the harness, focusing on the following:Condition of the wires (check for cuts, cracks, abrasions, fraying, or exposed conductors)Integrity of insulation and coverings (look for missing tape, damaged conduit, or heat damage).Condition of connectors (check for corrosion, broken clips, loose or bent pins).Signs of overheating (burn marks, melted insulation).Routing and securing (whether the harness is adequately supported, tied down, and clear of moving parts or sharp edges).The photo of the harness.A summary of your observations. Be sure that your observations use language represented in Any defects or concerns you noticed.A recommendation (e.g., “harness is acceptable for use,” “minor repair needed,” or “should be replaced”).
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Clarity and quality of photo (20%)Thoroughness of visual inspection (40%)Accuracy and detail of written observations (30%)Professionalism and organization of report (10%)
AT 209 Wiring Harness Inspection
Overview
This assignment guides students in visually inspecting a wiring harness to identify common defects such as damaged wires, poor connectors, or insulation issues. Students will document their findings with a photo and a brief report, developing essential skills in harness condition assessment for safety and reliability.
Resources
FAA AC 43.13-1B - Chapter 11, Sections 8-12
Assignment
Document Preparation
Photograph Wiring Harness
Report of Findings
Broken link
Photos
Inspection Report
For this assignment, I inspected a wiring harness located in the engine bay of my personal vehicle. The harness runs near the intake manifold and alternator, with multiple connections leading to sensors, power components, and a ventilation hose. I made sure to take a clear photo showing the connectors, wire coverings, and how the harness is routed and secured.
During the visual inspection, I didn’t notice any major damage or concerns. The wires looked to be in good shape, no cuts, cracks, fraying, or exposed copper anywhere I could see. Most of the wires are protected with a plastic corrugated loom, and that conduit is still intact and doing its job. I didn’t spot any signs of heat damage either, which is important considering how close this harness sits to some warmer engine parts.
All the connectors seem to be properly locked in place and aren’t cracked or loose. There wasn’t any corrosion or moisture around the plug ends either. The routing of the harness looked solid, with plastic clips and ties holding everything in place. It’s clear of any moving parts or sharp edges, and nothing is rubbing against the harness, which is a good sign.
The only thing worth keeping an eye on is the nearby hose clamp, it’s positioned fairly close to the harness near the alternator. It’s not causing any damage now, but if it shifts due to vibration over time, it could potentially wear into the wires. For now, though, it doesn’t appear to be a problem.
Overall, I’d say the wiring harness is in good condition and safe for continued use. No repairs are needed at this time, but a quick check during routine maintenance would be a smart idea just to make sure everything stays in place.
Deliverables
Evaluation Criteria
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