Connection Procedure Using Crimp Terminal

CAUTION:

• Always use the special service tool (49JP 03 001) when performing this procedure. If a similar tool other than the special service tool is used, the possibility of a poor connection occurring due to insufficient crimping is high even though it may appear that the crimping was done successfully.

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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 1	Compatible wiring size	Crimping area of special service tool 1
   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 detaches and open the handle of the special service tool.

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3. Place the appropriate crimp terminal on the crimping area of the special service tool and secure the crimp terminal by lightly squeezing the grips to a level that the crimping terminal does not deform.

   Courtesy of MAZDA MOTORS CORP.

   Courtesy of MAZDA MOTORS CORP.

   CAUTION:

   • Set the cutter blade of the special service tool inside the scribed line (cutter blade position indicator line of special service tool) on the crimp terminal.
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.

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5. Crimp the crimp terminal completely by squeezing the grips of the special service tool tightly until the ratchet detaches.
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°C {212°F} using a drier until the plastic melts on both ends.

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   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.