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Toyota Wiring (1991-2005 year). Instruction - part 4

Access Hole
(

Mark)

Special Tool

[Female]

[Male]

Terminal
Retainer

Special Tool

Special
Tool

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–14

Wire Harness Repair Instruction (RM1022E)

Type E (For 1.8, 2.3, 2.3II, 4.8, 6.3 and 8.0 of Waterproof
Type Connector)

HINT:

Terminal retainer color is different according to

connector body.
Example:
Terminal Retainer

Connector body

Black or White

Gray

Black or White

Dark Gray

Gray or White

Black

[Case 1]

Type where terminal retainer is pulled up to the
temporary lock position (Pull Type).

Example:

[Male]

[Female]

Temporary Lock Position

Terminal Retainer at
Full Lock Position

Access hole

B–15

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

(1)

Insert the special tool into the terminal retainer
access hole (

Mark) and pull the terminal 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.

HINT:

In some cases insert the special tool from the

access hole on the flank of the housing.

Example:

Terminal Retainer

Press Down

[Male]

[Female]

Example:

[Male]

[Female]

Retainer at
Full Lock Position

Retainer at
Temporary Lock Position

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–16

Wire Harness Repair Instruction (RM1022E)

[Case 2]

Type which cannot be pulled as far as Power Lock

HINT:

There are few cases of this type of connector

(1)

Insert the tool straight into the access hole of terminal
retainer as shown.

Push the terminal retainer down to the temporary lock
position.

Service hole

Retainer

Lock

Special tool

B–17

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

Type F (For C–Type Connector)

(1)

Insert the special tool into the service hole.

(2)

Move the special tool to the direction of the arrow and
release the lock.

HINT:

Lift the retainer up after moving it to the direction

of the thin arrow shown in the illustration.

(3)

Pull the retainer forward by hand and remove the
retainer from the housing.

Type G

Insert the special tool into the position shown in the
illustration. Pry it to the direction of the arrow and
push the lock up to release it.

Notch

Retainer
(Yellow)

Seal rubber

Condition of cover opening

Side Lock

Center Lock

Side Lock

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–18

Wire Harness Repair Instruction (RM1022E)

Type H (For 1.0II Type Connector)

(1)

Move the special tool into the notch of the retainer to
the direction of the arrow with the edge of the housing
as the fulcrum. Then the pull the retainer out.

NOTICE:
Do not insert the special tool into areas except
notches. (This may damage the seal ring that is
attached behind the retainer.)

(2)

As same as the procedure (1), pull the retainer
straight out using hand after releasing the lock on the
other side.

NOTICE:

Do not remove the seal rubber when pulling the
terminal out.

If the seal rubber is peeled off when puling the
terminal out, press it down to stick it to the original
condition.

Be sure and not fit the connector when the retainer
is not installed

Type I (For SFPC Type Connector)

(1)

Open the cover (white)

(2)

Remove the side lock of the retainer. (One side)

(3)

Remove the center lock of the housing.

(4)

Remove the side lock of the retainer. (The other side)

NOTICE:

Following the above order is not required.

No center lock on the housing with ten poles.

Initial condition

Retainer

Rubber Plug

Outer

Lock

Inner

Rubber Plug

Illustration from side B

Outer

Special tool

Inner

B–19

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

(5)

Move the retainer until it becomes the initial condition.

Type J

[Male]

(1)

Remove the rubber plug.

(2)

Push the lock of the inner using the special tool.

(3)

Pull the wire to the direction of the arrow pushing the
lock up and remove the inner from the outer.

[Female]

(1)

Remove the rubber plug.

(2)

Insert the special tool into the outer shown in the
illustration. Then push the area A of the inner and
remove the inner from the outer.

Special Tool

Lock

Special Tool

Cover

Special Tool

Raise Up

Special Tool

Special Tool
Insert Mark

Terminal
Retainer

Terminal Retainer

[Retainer at Full Lock Position]

Stopper

[Retainer at Temporary Lock Position]

Terminal
Retainer

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–20

Wire Harness Repair Instruction (RM1022E)

Type J (For Insulation Displacement Connector)

(1)

Separate Connector

Using a special tool, release the lock and separate the
connector into 2.

NOTICE:
Do not apply too muck force to the lock arm.

(2)

w/ Cover : Open Connector Cover

Using a special tool, release the lock and open the cover.

NOTICE:
Do not apply too much force to the lock arm.

Type K (0.64 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.

Good

Bad

Special Tool

Lock

Special
Tool

Special Tool

Lock

Special Tool

Lock Housing

Upper
Housing

B–21

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

Type L (0.64 of Insulation Displacement Connector (IDC)
Type)

(1)

Remove the Lower Housing

Using a special tool, release the lock and remove the lower
housing.

NOTICE:

Do not apply too much force to the lock arm.

Mark the upper housing and lower housing to
prevent mistakes when putting them together.

(2)

Remove the Upper Housing

Using a special tool, release the lock and remove the upper
housing from the lock housing.

NOTICE:

Do not apply too much force to the lock arm.

Mark the upper housing and lower housing to
prevent mistakes when putting them together.

Type M (0.64 of Splash Proof Connector)

(1)

Release Terminal retainer.

Insert Special Tool at the location shown in the figure
left.

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