Connector Inspection Procedure

Handling of Connector
1. Never pull on the wiring harness when disconnecting connectors.
  
  Fig 1: Caution For Pulling Wiring Harness
  Courtesy of KIA MOTORS AMERICA, INC.
2. When removing the connector with a lock, press or pull locking lever.
  
  Fig 2: Pressing And Pulling Locking Lever
  Courtesy of KIA MOTORS AMERICA, INC.
3. Listen for a click when locking connectors. This sound indicates that they are securely locked.
  
  Fig 3: 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: Caution For Measuring Voltage
  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: Caution For Waterproof Connector Terminals
  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 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.