TOYOTA SUPRA 1995 Service Repair Manual

TERMINAL AND CONNECTOR REPAIR±CONNECTOR REPAIR
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Wire Harness Repair Manual (RM1022E)
CONNECTOR REPAIR
The repair parts now in supply are limited to those connectors having common shapes and terminal
cavity numbers. Therefore, when there is no available replacement connector of the same shape or
terminal cavity number, please use one of the alternative methods described below. Make sure that the
terminals are placed in the original order in the connector cavities, if possible, to aid in future diagnosis.
1. When a connector with a different number of terminals
than the original part is used, select a connector
having more terminal cavities than required, and replace both the male and female connector parts.
EXAMPLE: You need a connector with six terminals, but the only replacement available is a connector
with eight terminal cavities. Replace both the male and female connector parts with the eight terminal part,
transferring the terminals from the old connectors to the new connectors.
2. When several different type terminals
are used in one connector, select an appropriate male and female
connector part for each terminal type used, and replace both male and female connector parts.
EXAMPLE: You need to replace a connector that has two different types of terminals in one connector.
Replace the original connector with two new connectors, one connector for one type of terminal, another
connector for the other type of terminal.
3. When a different shape of connector
is used, first select from available parts a connector with the
appropriate number of terminal cavities, and one that uses terminals of the same size as, or larger than,
the terminal size in the vehicle. The wire lead on the replacement terminal must also
be the same size as,
or larger than, the nominal size of the wire in the vehicle. (ºNominalº size may be found by looking at the
illustrations in the section F or by direct measurement across the diameter of the insulation). Replace all
existing terminals with the new terminals, then insert the terminals into the new connector.
EXAMPLE: You need to replace a connector that is round and has six terminal cavities. The only round
replacement connector has three terminal cavities. You would select a replacement connector that has
six or more terminal cavities and is not round, then select terminals that will fit the new connector. Replace
the existing terminals, then insert them into the new connector and join the connector together.
B

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TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (RM1022E)
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.
B

TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (RM1022E)
Step 1. Identify the connector and the terminal type.
Confirm whether the connector you require is the non±waterproof, waterproof or combined terminal type
connector from the pictures provided in the following charts.
Connector
Description
Non±Waterproof TypeThose connectors which are not of the
waterproof or combined terminal type.
Waterproof TypeWaterproof material (hole plug or terminal
packing) is provided on the terminal/connector
body.
Combined Terminal TypeTerminals of different shape/size are located in
one connector.
1. Terminal with Wire
Identify the part number of the terminal with wire by picking
out the corresponding illustration from the pictures
provided on the following charts.
HINT: In some of the illustrations, there are two part
numbers for the same illustration of terminal with wire,
because although the shapes of the terminals are
completely the same, there is a difference in with /without
gold±plating (gilded).
Remark: T h e length of the wire connected to the
terminal is approximately 150 mm.
B

Example:
Back of the
Connector Body
P/N 90980±10854
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Wire Harness Repair Manual (RM1022E)
NOTICE:

When the terminal used is gold plated, be sure to
replace it with a gold plated terminal when marking
repairs.

Do not use male and female terminals which are
made of different materials from each other.
2. Connector Body
(a)Identify the part number of the corresponding
terminal with wire according to the above±mentioned
1.
(b)Identify the part number of the connector body by
picking out the correct one from the illustrations
according to the number of terminals and the shape.
HINT:
(a)If you can find no connector which matches the type
you require, pick out male and female connector
bodies as a set which have more terminals than you
require.
For the combined terminal type connector body, pick
out and appropriate connector body for each terminal
being used.
Example:
When two types of terminal are used in one connector
body, pick out a male and female for two different
connector bodies.
(b)The part number has been stamped on the back of
the connector body. (This will continue to be done to
new types of connector.)
B

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 mmWire Outside
DiameterSleeve Size
(Color)
Small (Red) 0.2±1.0 mm
Wire Outside Diameter
Insulation Calipers
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (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
5S
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 EvenlyCalipers Nominal Size of WireWire Lead
Diameter
Wire Outside Diameter
Nominal Size
Insulation
Stripped Wire Harness Section
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TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (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 ºNominal Sizeº of the wire.
Nominal size =
3.14 x (Diameter of stripped wire harness)
2
4
HINT: Outside Diameter and Nominal Size
B

Example:
Press DownPress DownPull Up Pull Up
Refereance:
(mm)
Example:
Up
Tool
Terminal Retainer
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (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 RetainerSpecial
Tool
Terminal Retainer
[Retainer at Full Lock Position]
Stopper
[Retainer at Temporary Lock Position]Terminal
Retainer
Good Bad Good Bad
[Male] [Female]
Special Tool
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TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (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
Ta b
Open
*
* *
*Open
[Male][Female] * Double Locking Device.
Retainer
Side Lock
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (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
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TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (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.