Wire Harness Repair.pdf

B–3

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

TERMINAL REPLACEMENT

These steps must be followed when replacing a terminal.

Step 1. Identify the connector and the terminal type.

Step 2. Disconnect the terminal from the connector.

Step 3. Replace the terminal.

Step 4. Install the terminal into the connector.

Wire Harness Repair Manual (RM1022E)

FOREWORD

This manual has been prepared for use when

performing terminal repairs, wire repairs, or connector

repairs on vehicles.

A step–by–step section on connector repair and

terminal repair is included.

There is a section of charts with terminal and connector

illustrations, part numbers, and notes on terminal

removal.

By using this guide, a satisfactory repair of the wiring

harness and connectors in Toyota vehicles will be easy

to achieve.

All information in this manual is based on the latest

product information at the time of publication. However,

specifications and procedures are subject to change

without notice.

2002

reproduced or copied, in whole or in part, without the

written permission of Toyota Motor Corporation.

A–1

INTRODUCTION–GENERAL INFORMATION

GENERAL INFORMATION

This manual provides instruction in the following repairs:

How to Inspect for System Inspection

Circuit Protection

Terminal and Connector Repair Procedure

NOTICE:

When inspecting or repairing the SRS AIRBAG, be sure to carefully read the precautionary

instructions and procedure in the Repair Manual for the applicable model.

After any electrical repair is made, always test the circuit by operating the devices in the circuit. This

confirms not only that the repair is correct, but also that the cause of the complaint was correctly

identified.

Tab width

0.64 mm

Terminal type number name

The terminal type number naming system has changed:

the metric system will be used in place of the inch system.

To be more specific, male tab width ”in millimeters” will be

used as terminal type number from now on –– in place of

male tab width in inches which has been in use so far.

Below is a table of comparison:

Old terminal type No.

(inch)

New terminal type No.

(mm)

025

0.64

040 (II, III, IV)

1.0 (II, III, IV)

050

1.3

070 (II)

1.8 (II)

090 (II)

2.3 (II)

187

4.8

250 (II)

6.3 (II)

305

7.7

312

8.0

375

9.5

For those connectors which are not shown above, the

terminal type numbers remain unchanged.

Wire Harness Repair Manual (RM1022E)

A–2

INTRODUCTION–GENERAL INFORMATION

Terminal (Female)

What is Wire Harness?

The wire harness (W/H) is systems of electric wires for

automobiles to connect all the electronics parts in

automobile electrically and work them. As more electronics

parts are introduced in automobiles recently, the electric

wires used for the wire harness are increasing in number

and the structure is becoming more complicated. As a

result of that, there are hundreds of connectors, which is

the parts which connects wires mechanically and

electrically, in one vehicle. Therefore, numbers of the

connector terminal (Terminal) or the connector housing

(Housing) are designed to meet many kinds of uses of

circuits. Various components have been improved to

ensure the product reliability or realize a wider space in the

vehicles.

Wire Harness Components

Wire harness mainly consists of wires, terminals, or

housings.

There are various components are designed for many

parts of vehicles, such as one with high heat–resistance,

water–resistance, or bending ability, ones have different

current capacities, or ones are hardly influenced by

electromagnetic noise.

Electric Wire

The electric wires used for the wire harness consists of the

conductor made from numbers of twisted mild copper wire

with a diameter of less than 0.5 mm and the insulator

surrounding the conductor.

The insulator is generally made from vinyl chloride and

covers the conductor with even thickness. The insulators

are color–coded in order to distinguish each wire. The base

colors or the stripe patterns is used to make difference

between insulators. Each color of wires is indicated by the

abbreviation in the repair manual and the electrical wiring

diagram.

Housing (Female)

Housing (Male)

Terminal (Male)

Electric Wire

Terminal

Housing

Fuse

Wire

Harness

(W/H)

J/B

(Junction Block)

R/B

(Relay Block)

Other

Insulator

Copper Wires

(Conductor)

B = Black

W = White

L = Blue

BR = Brown

V = Violet

SB = Sky Blue

R = Red

G = Green

P = Pink

LG = Light Green

Y = Yellow

GR = Gray

O = Orange

Wire Harness Repair Manual (RM1022E)

A–3

INTRODUCTION–GENERAL INFORMATION

Example: L–Y

The first letter indicates the basic wire color and the second

letter indicates the color of the stripe.

–

(Blue)

(Yellow)

Terminal and housing

Terminal connects wires and housing insulates connecting

parts.

There are the male terminal and the female terminal. The

types of terminals are decided by tab width of male

terminal. And the terminal with the rubber plug or the

rubber ring is used in the part, such as the engine

compartment, which become wet. For the circuit with slight

current at EFI system or ABS system, the gold–plated

terminal is introduced for ensuring reliabilities.

As the number of the circuit is increasing recently, there are

new types of parts introduced. For example, there is the

hybrid type housing, which is a combination of terminals

with different tab width, such as the power source terminal

or the signal terminal. Also, new type of connector such as

the double lock housing, which is designed with the

retainer in addition to the lance to prevent terminal from

slipping off, is available. The new type of connectors are

produced to realize higher product reliabilities and utilized

widely recently. The major characteristics of these new

connectors are shown in the table 1.

There are two types of lances: housing lance, which is

inside the housing and terminal lance, which is inside the

terminal.

Tab width

1.3 mm

Rubber

Plug

Rubber Ring

Housing Lance

Type

Terminal Lance

Type

Wire Harness Repair Manual (RM1022E)

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