Connector Inspection Procedure

Handling of Connector
1. Never pull on the Wiring Harness when disconnecting Connectors.
  
  Fig 1: Caution For Handling Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
2. When removing the Connector with a lock, press or pull locking lever.
  
  Fig 2: Locating Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
3. Listen for a click when locking Connectors. This sound indicates that they are securely locked.
  
  Fig 3: Locking Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
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 Checking Tester Continuity
  Courtesy of HYUNDAI MOTOR AMERICA
5. Check Waterproof Connector Terminals from the Connector Side. Waterproof Connectors cannot be accessed from harness side.
  
  Fig 5: Caution For Checking Waterproof Connector Terminals
  Courtesy of HYUNDAI MOTOR AMERICA
  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 HYUNDAI MOTOR AMERICA
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.