Toyota Wiring (1991-2005 year). Manual - part 7

Temporary Lock Position

Full Lock Position

Terminal Retainer

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Type C (For 0.64 Type Connector)

(a)

Insert the terminal.

HINT:
1.

Make sure the terminal is positioned correctly.

2.

Insert the terminal with terminal retainer in the
temporary lock position.

(b)

Insert the terminal until the terminal lance locks firmly.

HINT:

1.

Pull the terminal back gently to check whether it is
locked correctly.

2.

If it cannot be inserted easily, check the terminal and
the connector for damage.

NOTE: If the terminal to terminal lance does not lock
firmly, the double locking device cannot lock or terminal
retainer does not lock at full lock position so the terminal
backs out from connector.

(c)

Close terminal retainer.

The connector is fitted with a terminal retainer, return
it to the full lock position.

Type D (For 0.64 Splash Proof Type Connector)

(a)

Verify that the terminal retainer is at unlocked
position.

Upper lock

Lower lock

Rear Holder

Housing rear end

Rear Holder

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Wire Harness Repair Manual (RM1022E)

(b)

Verify that Rear Holder is at unlocked position.

NOTICE:
If Rear holder or wire seal has been removed, replace
it with new one.

(c)

Insert the terminal fully into the housing until it is
locked.

HINT:

The terminal has a longer insertion stroke than

conventional ones.

(d)

Set Rear holder to locked position.
Push Rear holder in the direction of arrow until it is
locked.

(e)

Verify that Rear holder is at the specified position.
The rear end of Rear holder is flush with the rear end
of Housing.

Lock check position, upper

Lock normal engagement position

Incomplete lock engagement

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Manual (RM1022E)

Verify that the lock (upper side) is at the specified position
under locked status.

Lock normal engagement position

Incomplete lock engagement

Lock check position, lower

Insert Special Tool

Special Tool 
hole
(U shaped)

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Wire Harness Repair Manual (RM1022E)

Verify that the lock (lower side) is at the specified position
under the locked status.

(f)

Set Terminal retainer to Lock position.
Insert Special tool into the hole specified in the left
and push Terminal retainer.

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Wire Harness Repair Manual (RM1022E)

(g)

Verify that Terminal retainer is inserted to the
specified position.

NOTICE:
If Terminal retainer is stopped at its middle of insertion,
holding wire, push Terminal to help it for full insertion.

A

A

A

B

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Wire Harness Repair Manual (RM1022E)

SPECIAL EXAMPLE

First fit the section A.

Install the lock of the section A first.

Install the lock of the retainer and pull the white cover
until you hear a click sound.

Install the convex part (A) of the outer part correctly to
the section B of the inner part.

Cover

Fix Band

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Wire Harness Repair Manual (RM1022E)

Insulation Displacement Connector

w/ Cover : CLOSE COVER

NOTICE:
Securely lock it

HINT:
When replacing it to a new connector, cut off the fixing band
without leaving it.

UNITE CONNECTOR

Make the projection of the front lock of the upper housing
meet the ditch of the front lock of the lower housing and fix
the rear lock.

NOTICE:

After uniting, securely lock it for not leaving the rear
lock arm deformed.

Make sure that the terminals will not become loose
by pulling the wires lightly.

Upper Housing

Lock Housing

Lower
Housing

Upper Housing Attached Lock Housing

Wire

Pull

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Wire Harness Repair Manual (RM1022E)

Insulation Displacement Connector (0.64 Type)

(a)

Install the upper housing to the lock housing.

NOTICE:

Securely Lock it.

Be careful not to mistake the upper housing and
lower housing when putting together.

(b)

Make the projection of the front lock of the upper
housing attached lock housing meet the ditch of the
front lock of the lower housing and fix the rear lock.

NOTICE:

Afteruniting, securely lock it for not leaving the rear
lock arm deformed.

Make sure that the terminals will not become loose
by pulling the wires lightily.

Be careful not to mistake the upper housing and
lower housing when putting together.

3.

When properly installed, pulling gently on the
wire lead will prove the terminal is locked in the
connector.