Connection Procedure Using Crimp Terminal

CAUTION:

• Always use the special service tool (49 JP03 001) when performing this procedure. Even though it may appear that the crimping was done successfully using a similar tool other than the special service tool, the possibility of a poor connection occurring due to insufficient crimping is high.

Fig 1: Insufficient Crimping (1) And Insufficient Crimping (2)

Courtesy of MAZDA MOTORS CORP.

1. Select the appropriate crimp terminal and the crimping area of the special service tool according to the thickness of the wiring harness to be repaired.

   Size (mark)	Outer diameter	Adaptation wiring size	Crimping area of special service tool
   S	3 mm {0.1 in}	0.5-1.0 sq	1.25
   M	4 mm {0.2 in}	1.25-2.5 sq	2

2. Squeeze the grips tightly until the ratchet of the special service tool is detached to open the handle of the special service tool.
   Fig 2: Squeezing Grips Tightly Of Special Service Tool

   Courtesy of MAZDA MOTORS CORP.
3. Place the appropriate crimp terminal on the crimping area of the special service tool, lightly close the grips so that the crimping terminal does not deform, and then secure the crimp terminal.
   CAUTION:

   • Set the cutter blade part of the special service tool inside the scribed line (position indicator line of special service tool) on the crimp terminal.
   Fig 3: Setting Cutter Blade Part Of Special Service Tool Inside Scribed Line (1 Of 2)

   Courtesy of MAZDA MOTORS CORP.
   Fig 4: Setting Cutter Blade Part Of Special Service Tool Inside Scribed Line (2 Of 2)

   Courtesy of MAZDA MOTORS CORP.
4. Insert the wiring harness to be connected into the crimp terminal until it reaches the contact point inside the terminal.
   CAUTION:

   • Verify that all the cores have been inserted without buckling.
   Fig 5: Inserting Wiring Harness To Be Connected Into Crimp Terminal

   Courtesy of MAZDA MOTORS CORP.
5. Squeeze the grips tightly until the ratchet of the special service tool is detached to crimp the crimp terminal flat.
6. Pull on the connected wiring harness to verify that the wiring harness does not pull out of the crimp terminal.
7. Perform the same procedure from Steps 3 to 6 for the opposite side.
8. Set the heat-shrinkable tubing to the connection area so that it is centered and shrink the heat-shrinkable tubing at a temperature of approx. 100 degrees C using a drier until the plastic melts on both ends.
   CAUTION:

   • Completely shrink the heat-shrinkable tubing to the wiring harness leaving no gaps.
   • Perform the work being careful not to melt the insulation of the wiring harness due to excessive heat.
   Fig 6: Shrinking Heat-Shrinkable Tubing To Wiring Harness Leaving No Gaps

   Courtesy of MAZDA MOTORS CORP.