Connector Inspection Procedure

Handling of Connector
1. Never pull on the wiring harness when disconnecting connectors.
  
  Fig 1: Precaution For Handling Of Connector
  Courtesy of KIA MOTORS AMERICA, INC.
2. When removing the connector with a lock, press or pull locking lever.
  
  Fig 2: Precaution For Removing Connector With A Lock
  Courtesy of KIA MOTORS AMERICA, INC.
3. Listen for a click when locking connectors. This sound indicates that they are securely locked.
  
  Fig 3: Precaution For Locking Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
4. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness side.
  
  Fig 4: Precaution For Checking Continuity
  Courtesy of KIA MOTORS AMERICA, INC.
5. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side.
  
  Fig 5: Precaution For Checking Waterproof Connector
  Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Use a fine wire to prevent damage to the terminal.
- 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 bend.
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 KIA MOTORS AMERICA, INC.
Repair Method of Connector Terminal
1. Clean the contact points using air gun and/or shop rag.
  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.