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: Locking Levers And Connector Locks
  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 Connectors For Click Sound
  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 Checking Wire Harness Continuity
  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
  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 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.