Toyota Wiring (1991-2005 year). Instruction - part 3

Hole Plug

Connector Body

Terminal 
Packing

Small (Red)

Large (Yellow)

Medium (Blue)

Medium (Blue)

1.0–2.0 mm

Large (Yellow)

3.0–5.0 mm

Wire Outside

Diameter

Sleeve Size

(Color)

Small (Red)

0.2–1.0 mm

Wire Outside Diameter

Insulation

Calipers

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–6

16

Wire Harness Repair Instruction (RM1022E)

3.

Hole Plug/Terminal Packing

(a)

Identify the part number of the appropriate terminal
with wire/connector body from the illustrations of
waterproof type connector according to the
above–mentioned  1 and 2.

(b)

Identify the part number of the hole plug/terminal
packing from the corresponding illustration.

4.

Sleeve

When connecting two wires using a sleeve, select the
sleeve according to the following table.

(a)

When size is based on the outside diameter of the
wire.

B

0.3

0.5

0.85

1.25

2

3

5

S

M

M

M

M

L

L

0.3

M

M

M

M

M

L

L

0.5

M

M

M

M

L

L

L

0.85

M

M

M

M

L

L

L

1.25

M

M

L

L

L

L

––

2

L

L

L

L

L

L

––

3

L

L

L

L

––

––

––

5

∗

 Nominal size of the wire

∗ ∗

Twist Evenly

Calipers

Nominal Size of Wire

Wire Lead
Diameter

Wire Outside Diameter

Nominal Size

Insulation

Stripped Wire Harness Section

B–7

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

17

Wire Harness Repair Instruction (RM1022E)

(b)

When size is based on the nominal size of the wire.

Sleeve size
S : Small (Red)
M : Medium (Blue)
L : Large (Yellow)

HINT:

To calculate the ”Nominal Size” of the wire.

Nominal size =

3.14 x (Diameter of stripped wire harness)

2

4

HINT:

Outside Diameter and Nominal Size

B

Example:

Press Down

Press Down

Pull Up

Pull Up

Refereance:

(mm)

Example:

Up

Tool

Terminal Retainer

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–8

18

Wire Harness Repair Instruction (RM1022E)

Step 2.

Disconnect the Terminal from the Connector.

1.

Disconnect Connector

To pull apart the connectors, pull on the connector itself,
not the wire harness.

HINT:

Check to see what kind of connector you are

disconnecting before pulling apart.
Press down type is mainly used.

2.

Prepare the Special Tool

HINT:

To remove the terminal from the connector, please

construct and use the special tool or like object shown on
the left.

3.

Disengage the double locking device or terminal
retainer.

(a)

Locking device must be disengaged before the
terminal locking clip can be released and the terminal
removed from the connector.

(b)

Use a special tool or the terminal pick to unlock the
double locking device.

NOTICE:
Do not remove the terminal retainer from connector
body.

B

Raise Up

Terminal Retainer

Special
Tool

Terminal Retainer

[Retainer at Full Lock Position]

Stopper

[Retainer at Temporary Lock Position]

Terminal
Retainer

Good

Bad

Good

Bad

[Male]

[Female]

Special Tool

B–9

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

19

Wire Harness Repair Instruction (RM1022E)

Type A (For 1.0II, 1.8, 2.3II, 4.8 and 8.0 of Non–Waterproof
Type Connector)

(1)

Using the special tool, raise the retainer up to the
temporary lock position.

HINT:

The needle insertion position varies according to

the connector’s shape (number of terminals, etc.), so
check the position before inserting it.

Type B (For 1.8, 1.0 and TLC of Non–Waterproof Type
Connector)

B

Access Hole

Tab

Open

∗

∗

∗

∗

Open

[Male]

[Female]

∗

 Double Locking Device.

Retainer

Side Lock

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–10

20

Wire Harness Repair Instruction (RM1022E)

(1)

Press the special tool at a 45

°

 angle into the locking

lug access hole as shown.

Raise the double locking device up as far as possible.

(2)

Remove the special tool and open the double locking
device

NOTICE:
TLC housing is not be reusable. Please replace it with
the new one after replacement of the terminal.

Type C (For TNS, FTC Type Connector)

(1)

Widen the side lock part of the retainer from side to
side using the special tool.

B

Special tool

Lock

∗

∗

∗

∗

∗

 Double Locking Device.

Special Tool

B–11

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

21

Wire Harness Repair Instruction (RM1022E)

(2)

Inset the special tool into the chink between the
retainer and the terminal itself. Then pry it to the
direction of the arrow shown in the illustration and
push the retainer up to release the lock.

NOTICE:

Do not insert the special tool too much. It may cause
damage on the fit section of the terminal and the
wire harness.

TNS housing is not reusable. Please replace it with
the new one after replacement of the terminal.

Type D (For 1.3 of Non–Waterproof Type Connector)

[Case 1]

(1)

Use the special tool to unlock the double locking
device.

Special Tool

Special Tool

Locking
Lug

Locking
Lug

Terminal
Retainer

[Retainer at Full Lock Position]

[Retainer at Temporary Lock Position]

Terminal Retainer

[Retainer at Full Lock Position]

Stopper

[Retainer at Temporary Lock Position]

Terminal
Retainer

Special
Tool

Service hole

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–12

22

Wire Harness Repair Instruction (RM1022E)

[Case 2]

(1)

Using the special tool, push the terminal retainer
locking lug (clip) and pull the terminal retainer up to
the temporary lock position.

[Case 3]

(1)

Using the special tool, raise the retainer up to the
temporary lock position.

[Case 4]

Appearance when the double 
locking is released

A

Special tool

B

B–13

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

23

Wire Harness Repair Instruction (RM1022E)

(1)

Insert the special tool into the service hole and move
it to the direction of the arrow to release the lock on
the side A.

(2)

Push the lock on the side B up by the special tool and
release the lock. Then pull the retainer forward.