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Toyota Wiring (1991-2005 year). Instruction - part 5

Terminal Retainer

[Retainer at Lock Position]

[Retainer at Unlock Position]

Terminal Retainer

Rear Holder

[Rear Holder at Lock Position]

[Rear Holder at Unlock Position]

Rear Holder

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–22

Wire Harness Repair Instruction (RM1022E)

Move Special Tool in the direction of arrow.

(2)

Release Rear holder.
Insert Special Tool at the location shown in the figure
left.

Move Special Tool in the direction of arrow.

NOTICE:

Do not remove Rear holder from Connector
housing.

If Rear holder completely comes off the housing,
replace Connector with a new one.

Rear Holder

Locking Clip

Pull Out

Connector

Wire Harness

Terminal
Retainer

Locking
Clip

”Waterproof Type”

Special
Tool

B–23

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

Disconnect Terminal from Connector

(a)

Determine the primary locking system from the
charts.
1. Lock Located on terminal
2. Lock Located on connector
3. Method of entry and operation

(b)

Push the terminal gently into the connector and hold
it in this position.

(c)

Insert the special tool into the connector in the
direction shown in the chart.

(d)

Move the locking clip to the unlock position and hold
it there.

NOTE: Do not apply excessive force to the terminal.
Do not pry on the terminal with the special tool.

(e)

Carefully withdraw the terminal from the connector by
pulling the lead toward the rear of the connector.

NOTE: Do not use too much force. If the terminal
does not come out easily, repeat steps (a) through
(e).

Locking Clip

Terminal Retainer

4.8 Type

”Non–Waterproof Type”

SST

Tool Hole

Terminal Lance

Stopper Portion

0.64 Type

Non–waterproof type TLC housing

Insert the tool from wire harness side

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–24

Wire Harness Repair Instruction (RM1022E)

(f)

Insert the SST into the connector in the direction
shown in the chart.

(g)

Insert the SST fully to the tool hole, and push the
terminal lance.

NOTICE:

The terminal has a lance shape, therefore, the
housing may be damaged and the terminal may get
stuck if forcibly pried by wires etc.

Insert the SST so that the stopper portion surface is
facing up.

(h)

Carefully withdraw the terminal from the connector by
pulling the lead toward the rear of the connector.

NOTICE:
Removal of the terminal from housing cavity will cause
damage to the wire seal section, deteriorating
waterproofing performance. Replace the connector
with a new one.

NOTICE:
Do not insert the special tool into the female terminal
box. If you do so, replace the terminal with the new one
whether the terminal is broken or not.

NOTICE:
As for Non–waterproof type TLC housing, insert the
special tool into the housing from wire harness side.

Tool Hole

Terminal Lance

Special
Tool

Tool Hole

Special Tool

Terminal
Lance

Special Tool

0.64 Type

B–25

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

Insulation Displacement Connector Type

(a)

Using a special tool, push the terminal lance from the
tool hole.

(b)

Carefully withdraw the terminal from the connector by
pulling the lead toward the rear of the connector.

NOTICE:

Do not use too much force. If the terminal does not
come out easily, repeat step (a).

Always change the wire with the repair wire, in
accordance with page B–27.

Terminal Deformation

(1)

Terminal Bending in Vertical Direction

(2)

Terminal Bending in Horizontal Direction

or less

3°

or less

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–26

Wire Harness Repair Instruction (RM1022E)

Inspect the terminal and the connector for
damage.

NOTE:

The locking clip is easily damaged.

Do not reuse the damaged part.

Step 3.

Replace the terminal.

Cut

Existing
terminal

New Terminal with lead

82998–12200

Stripped insulation length (A)
approximately 8 to 11 mm

Existing
Harness

Supplied lead
with New Terminal

B–27

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

Cut the Old Terminal from the Harness.

(a)

Use the new wire lead as a guide for proper length.

NOTE: If the length of wire removed is not
approximately the same length as the new piece, the
following problems may develop:

Too short –– tension on the terminal, splice, or
the connector, causing and open circuit.

Too long –– excessive wire near the connector,
may get pinched or abraded, causing a short
circuit.

HINT:

When connecting a wire harness at there or more

spots to the same connector, cut the wire harness as
shown on the left.

Select the correct replacement terminal with
lead, from the supply parts.

Strip insulation from wire on the harness and
replacement terminal lead.

Start stripping at least 8 mm (0.31 in.) to 11 mm (0.43 in.)
away from the end of the existing harness at vehicle side
and also from the end of the repair wire.

Good Example:

Bad Example:

(Wire insulation is Stripped at a Slant)

(Wire Lead is Cut)

(Insulation Remains on the Lead)

Wire Harness Outside Diameter

Insulation

Calipers

Nominal Size of the Wire

Twist Evenly

Calipers

Wire Lead
Diameter

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–28

Wire Harness Repair Instruction (RM1022E)

NOTICE:
Take care not to damage the wire when stripping the
wire harness lead. After finishing the operation,
visually inspect the wire. If there is any damage,
perform the operation again.

HINT:
If the wire size is not known, start with largest stripper hole
and work down until a clean strip of the insulation is
removed without nicking or cutting the wire lead.

Select Correct Size of Sleeve from the Supply
Parts.

(a)

Measure the diameter of wire by using the measuring
device as following:

When size is based on the outside diameter of the
wire harness
Measure the outside diameter of the wire harness by
placing a measuring device, such as a micrometer or
Vernier Caliper, across the diameter of the insulation on
the lead and taking a reading.

When size is based on the nominal size of the wire
lead.
Measure the diameter of the wire lead by placing a
measuring device, such as a micrometer or Vernier
Caliper, across the diameter of the wire lead and taking
a reading.

HINT:
To calculate the ”nominal size” of wire

Nominal size=

3.14 x (Diameter of wire lead)

Small (Red)

Medium (Blue)

Large (Yellow)

Good Example

Two Stripped Wires

Sleeve (Blue)

Bad Example

Pressure–Contact
Section

Wire in
Short Position

Wire Bend

Special Tool

B–29

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

(b)

Use the table to determine proper sleeve size

Part Number

Nominal size of wire
(Outside Diameter of
wire)

Small

82999–12010

0.3 or less
(1.0 – 0.2 mm)

Medium

82999–12020

0.5 – 1.25
(2.0 – 1.0 mm)

Large

82999–12030

2 or more
(5.0 – 3.0 mm)

NOTE: For details, refer to sleeve size table on item
4 of STEP 1

Crimp the Replacement Terminal Lead to the
Harness Lead.

(a)

Overlap the two stripped wire ends inside the sleeve
as illustrated on the left.

HINT:

You might find it easier if you use a miniature

special tool as a guide as you insert wires into the sleeve.

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