Replacement Wire Repair Connectors (GEN082)

REPLACEMENT WIRE REPAIR CONNECTORS

TECHNICAL SERVICE BULLETIN

SERVICE INFORMATION

This TSB provides information about wire harness connector repair. Replacement connectors allow for a more efficient repair of the wiring harness without replacing the assembly. The Service Information provides all of the necessary information needed to select the appropriate connector.

In the Electrical Troubleshooting Manual (ETM) located in KGIS, technicians will find part numbers of individual connectors, organized by number of cavities, to help simplify connector ordering.

In addition, the Kia Electronic Parts Catalog (EPC) includes a Wire Harness Repair Kit section listing all available wire harness connectors for each vehicle. The EPC listing is arranged by number of connector cavities for convenience and includes color photographs of each connector part number for easy identification. Refer to TSB GEN 083 for information on the new Wire Harness Repair Kit IV.

ACCESSING WIRE REPAIR INFORMATION

1. Login to KGIS and select vehicle model being worked on and go to ETM section.
2. Select "Wiring Repair Connector Catalog"

SELECTING THE CONNECTOR

1. Connectors are indexed by number of cavities from 1 to 26.
2. Connector part numbers that are marked in red, provide information about the Wire Repair Kit that carries the connector needed.

PARTS AND TOOLS NEEDED FOR ELECTRICAL CONNECTOR REPLACEMENT

Tool	Image	Tool	Image
Stripper / Crimper		Soldering Iron (Technician Supplied Tool)
Heat Gun (Technician Supplied Tool)		Crimp Connectors and Heat Shrink Tubing

SERVICE PROCEDURE

Follow the procedure listed below when performing connector repair.

1. Store radio presets or use a power/memory saver device
2. Disconnect the battery negative (-) terminal.
3. New connector wire colors are black; therefore, match the wire sequence/terminal cavity with damaged connector when reconnecting. Or label individual wires on replacement connector with colors of the original wires.
   NOTE: Wire size of the new connector should be the same or larger than the old wire. Never use smaller wire than original.
4. Cut the wires in a stagger pattern to facilitate wire repair and to reduce wire harness diameter increase from crimp connector, and insulation being "stacked" in one place.
5. Strip about 3/8" on each end of the wires using stripping tool.
6. Cut off the shrink tubes as needed and place onto the wire.
7. Insert the crimp connector into the Multi-Purpose Crimper. Care should be taken to assure the connector is positioned correctly in the crimpers.
8. Carefully insert the stripped wires into the connector. With the wires held in place, crimp connector onto the wire.
9. Adding solder to the crimp connector will improve the connection and the repair.
   NOTE: Refer to Technician Basics TB023 for soldering wire procedure.
10. Move the shrink tubes on the crimped inline connectors.
11. Using heat gun, heat the shrink tubes to a good seal.
12. Place the split plastic harness cover back onto the repaired wiring and reconnect the connector.
    NOTE: Electrical tape can also be used to cover the wires
13. Reconnect the negative (-) battery cable.
14. Use the KDS/GDS or other means to verify the function of the repaired circuit
15. Restore previously recorded radio presets.