Female Terminal Fitting Test Procedure

Refer to the wiring diagram and verify the location, size, and surface finish plating of the terminal to be tested.

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Disconnect the negative battery terminal.

Disconnect the connector of the terminal to be tested.

CAUTION:

When performing the fitting test, always use a tool compatible with the surface plating material of the terminal. The terminal surface plating is either gold, silver, or tin (None). Using a tool made of different material may damage the surface plating of the terminal. If the surface plating is damaged, the terminal may erode.

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Do not use a tool with scratched surface plating. Using a tool with scratched surface plating may damage the surface plating of the terminal. If the surface plating of the tool is damaged, replace the tool with a new one.
Surface damage is difficult to see. Therefore, always use a magnifying glass when inspecting the condition of the surface plating.

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Select a suitable tool from the fitting test kit with a size and surface plating that matches the terminal.
CAUTION:
- Slowly insert the tool into the female terminal, and keep the tool in line with the terminal wherever possible.
- If the tool is inserted at an angle or wiggled into the female terminal, the terminal may be damaged.
- Hold the wing portion of the tool with your fingers (if applicable), or the wiring harness, approximately 20 mm {0.79 in} away from the terminal portion of the tool. If the tool is inserted by holding the terminal portion of the tool, deformation of the female terminal opening can occur due to excessive force.
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Insert the tool into the female terminal, then slowly pull it out.
- The inspection is completed if it can be determined that the terminal connection is good based on how firmly the tool can be inserted and removed.
NOTE:
- Terminal size L is the largest size terminal tool. It may be difficult to insert it into a female terminal when holding the wiring harness due to excessive resistance. If it appears that the tool may be difficult to insert, confirm that the female terminal is in good condition, prior to inserting the tool.
- If the tool cannot be inserted or removed firmly and the condition of the female terminal cannot be determined, go to the next step.
CAUTION:
- If the condition of the female terminal cannot be clearly determined, find the same size and surface treatment of the terminal in a different location to compare the connection firmness. Confirm the terminal location by referring to the wiring diagram.
Compare the connection firmness by inserting the tool into an identical terminal (same size and surface treatment) in the same connector.
- If the connection is not correct, replace the wiring harness or connectors including the malfunctioning terminal. (Refer to the repair connector replacement procedure.)