Toyota Wiring (1991-2005 year). Manual - part 8

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Manual (RM1022E)

NOTICE:
If you working on the waterproof type, make sure that
a rubber plug or a terminal gasket is inserted into the
housing securely.

4.

Secure the Repaired Wire to the Harness

If the wire is not in the conduit, or secured by other means, wrap
vinyl tape around the bundle to keep it together with the other
wires.

5.

Connect Connector

Fit the male connector to the female terminal.

NOTICE:

Do not twist the connector when fitting.

Insert it until fully locked.

Lever

Lever

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TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS

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Wire Harness Repair Manual (RM1022E)

HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS

Low Fit and Lever Type Connector

[Case 1]

1.

Cut the connection of the connector

(1)

Push the place indicated by the arrow.

(2)

The lock is released and lever is lifted up.

(3)

Lift the lever up until it stops.

 an

(4)

Cut the connection of the connector.

NOTICE:
Do not hold the wire harness to pull it.

2.

Connect the connector

(1)

Connect the connector in the condition that the lever
is fully lifted up.

HINT:

If the lever is locked at the lower position, follow

the procedure [Case 1]. (1) to (3) and lift the lever up fully.

Lever

Lever is not locked

Lever

TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS

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(2)

Hold the connector to prevent it from slip off and push
it down until you hear a click to lock it.

(3)

Confirm that the lever is securely locked.

[Case 2]

1.

Cut the connection of the connector

(1)

Hold the area indicated by the arrow in the illustration

(2)

The lock is released and the lever is lifted up.

(3)

Lift the lever up fully.

(4)

Cut the connection of the connector.

NOTICE:
Do not hold the wire harness to pull it.

Lever

Lever is not locked

Lever

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TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS

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Wire Harness Repair Manual (RM1022E)

2.

Connect the connector

(1)

Connect the connector in the condition that the lever
is fully lifted up.

(2)

Hold the connector to prevent it from slip off and push
it down until you hear a click to lock it.

(3)

Confirm that the lever is securely locked.

[Case 3]

1.

Cut the connection of the connector

(1)

Pick the part indicated in the illustration by fingers.

(2)

The lock is released and the lever is lifted up.

(3)

Lift the lever up fully.

Lever

Lever is not locked

TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS

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Wire Harness Repair Manual (RM1022E)

(4)

Cut the connection of the connector.

NOTICE:
Do not hold the wire harness to pull it.

2.

Connect the connector

(1)

Connect the connector in the condition that the lever
is fully lifted up.

HINT:

If the lever is locked at the lower position, follow

the procedure [Case 3]. (1) to (3) and lift the lever up fully.

(2)

Hold the connector to prevent it from slip off and push
it down until you hear a click to lock it.

(3)

Confirm that the lever is securely fitted

Coil spring

Pin

Convex part

Double

 

locking 
device pin

Primary locking
device

Lock

Lock

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Wire Harness Repair Manual (RM1022E)

The connector with secondary locking
device

1.

Area used

Wire harness for SRS airbag deployment

2.

Cut the connection of the connector.

(1)

Release the double locking.

(2)

Release the primary locking and separate the
connector.

NOTICE:
Do not hold the wire harness to pull it.

3.

Connect the connector

(1)

Install the primary locking device and connect the
connector.

(2)

Install the double locking device.

NOTICE:
The double locking device can not be installed unless
the primary locking device is installed.

Connector A

Connector B

Connector A

Lass than 1mm

Connector B

Bolt

Cross–section of the bolt

TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS

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Connector fixed by bolts

1.

Area used

Engine control computer harness

2.

Cut the connection of the connector.

(1)

Remove the connector A.

(2)

Loose the bolt using a tool like driver until the
connector B can be removed by hand and separate
the connector.

HINT:

If the bolt can not be removed, roll it while pulling

forward.

3.

Connection of the connector

(1)

Temporarily fit the connector B.

(2)

Tighten the bolt by using tool like driver and fit the
connector B completely.

NOTICE:

Tighten the bolt until feeling it lighter. Then confirm
that the width of chink of the connector B is less
than 1mm.

The bolt can be rolled after it is fitted.

If the impact wrench is used, do not let it rolling
more than three seconds. (The housing may be
deformed by generated heat)

Be sure and connect the connector B straight.  Do
not incline it while connecting.

(3)

Connect the connector A.

Locking Arm

Hold back 
rib to pull 
connector

back ribs

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Wire Harness Repair Manual (RM1022E)

1.

Cut the connection of the connector

(1)

Push down on locking arm to unlock. Then hold the
back ribs of connector to remove connector.

(2)

Cut the Connection of the connector.

NOTICE:
Do not hold the wire harness to pull it.

2.

Connect the Connector

(1)

Align the direction of locking feature in same direction
and mate the connector holding the back ribs in
straight direction.

(2)

Insert it until a lock securely locks, and pull the
connector lightly after the insertion, and confirm that
a lock is enabled.