How To Install New Terminals

Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate.
NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures.
Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool.

Fig 1: Identifying Size Slot In Crimping Tool (204-5)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.)
NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again.

Fig 2: Striping Insulation Off End Of Wire (204-5)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former.

Fig 3: Positioning Terminal In Crimping Tool Slot With Solid Portion Of Terminal Toward Anvil And Open Section Toward Former (204-6)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Insert the wire in the terminal to the position shown in step 3.
Squeeze the tool with both hands until the stops make contact.

Fig 4: Identifying Crimping Tool Stops (204-6)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Crimp the insulation crimp.
- If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact.
- If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape.
  
  Fig 5: Identifying Insulation Crimp Making Full-Circle Shape (204-6)
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over.

Fig 6: Inspecting Quality Of Wire Crimp - Wire Should Be Visible (204-6)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 7: Inspecting Quality Of Wire Crimp - Wire Crimp Is Crimping On Insulation, Not Wire (204-6)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 8: Inspecting Quality Of Wire Crimp - Loose Strands Of Wire (204-6)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 9: Inspecting Quality Of Wire Crimp - Wire Crimp Not Crimped Evenly (204-6)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 10: Inspecting Quality Of Wire Crimp - Crimped Edges Should Be Even (204-6)
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 11: Inspecting Quality Of Wire Crimp - Poor Crimping (204-6)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place.
Close or insert the secondary terminal lock, if applicable, and reconnect the connector.