Connector Inspection Procedure

Handling of Connector
1. When disconnecting the connectors, pull on the connector, not the wiring harness.
  
  Fig 1: Caution For Disconnecting Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
2. When removing the connector with a lock, press or pull locking lever.
  
  Fig 2: Removing Connector With Lock
  Courtesy of HYUNDAI MOTOR AMERICA
3. When connecting the connectors, check whether a clicking sound is heard to make sure that the connectors are securely connected.
  
  Fig 3: Checking Whether Clicking Sound Heard To Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
4. When a tester is used to check for continuity, or to measure voltage, always insert the test probe in the wiring harness side.
  
  Fig 4: Caution For Inserting Test Probe In Wiring Harness Side
  Courtesy of HYUNDAI MOTOR AMERICA
5. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed through the harness side.
  
  Fig 5: Caution For Checking Waterproof Connector Terminals From Connector Side
  Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
- Use a fine wire to prevent the terminal from being damaged.
- Do not damage the terminal when inserting the tester lead.
Checking Point for Connector
1. While the connector is connected:
  Hold the connector, check connecting condition and locking efficiency.
2. When the connector is disconnected:
  Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
  
  Visually check for rust, contamination, deformation and sagging.
3. Check terminal tightening condition:
  Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
4. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
Fig 6: Pulling Lightly On Individual Wires
Courtesy of HYUNDAI MOTOR AMERICA
Repair Method of Connector Terminal
1. Clean the contact points using air gun and/or a cotton towel.
  NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may be damaged.
2. In case of abnormal contact pressure, replace the female terminal.