TOYOTA SUPRA 1995 Service Repair Manual

Terminal Retainer
[Retainer at Lock Position]
[Retainer at Unlock Position]Terminal Retainer
Rear Holder
Rear Holder
[Rear Holder at Lock Position]
[Rear Holder at Unlock Position]Rear Holder
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±22
32
Wire Harness Repair Manual (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 ºWaterproof Typeº
Special
Tool
B±23
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
33
Wire Harness Repair Manual (RM1022E)
4. 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 ºNon±Waterproof Typeº
SST Tool Hole
Terminal LanceStopper Portion 0.64 Type
Non±waterproof type TLC housing
Insert the tool from wire harness side
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±24
34
Wire Harness Repair Manual (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 LanceSpecial
Tool
Special
Tool
Tool HoleSpecial Tool
Terminal
Lance Special Tool 0.64 Type
B±25
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
35
Wire Harness Repair Manual (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 Direction1° or less
1° or less
3° or less
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±26
36
Wire Harness Repair Manual (RM1022E)
5. 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
HarnessSupplied lead
with New Terminal AA
B±27
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
37
Wire Harness Repair Manual (RM1022E)
1. 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.
2. Select the correct replacement terminal with
lead, from the supply parts.
3. 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 EvenlyCalipersWire Lead
Diameter
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±28
38
Wire Harness Repair Manual (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.
4. 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 ºnominal sizeº of wire
Nominal size=3.14 x (Diameter of wire lead)
2
4

Small (Red)
Medium (Blue)
Large (Yellow)
Good Example
Two Stripped Wires Sleeve (Blue)
Bad ExamplePressure±Contact
Section
Wire in
Short PositionWire Bend
Special Tool
B±29
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
39
Wire Harness Repair Manual (RM1022E)
(b)Use the table to determine proper sleeve size
Part NumberNominal 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
5. 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.

Sleeve Color MarksCrimping
Tool
ºCLOSE HEREº
Contact
ºINSº Position
10 mm (0.39 in.)
Three or More Times
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±30
40
Wire Harness Repair Manual (RM1022E)
(b)The crimping tool (AMP Part No. 169060) has color
marks on it. Place the sleeve in the correct section of
the tool according to the color of the sleeve itself.
HINT: For the crimping tool, AMP ºPart No. 169060º is
convenient to use.
(c)With the center of the sleeve correctly placed
between the crimping jaws, squeeze the crimping tool
until either end comes into contact at the section
marked by ºCLOSE HEREº.
HINT: Check to see that the sleeve and wires are still in
the correct position before closing the crimping tool ends
with steady pressure.
(d)Pull the joined wires to either end. Make sure that they
are joined firmly by the sleeve.
NOTICE:
If the joined wires come loose the splice is defective,
so replace the sleeve and repeat the procedure.
(e)Crimp both ends of the sleeve with the crimping tool
at the ºINSº position.
6. Protect Joined Section
Wrap silicon tape around the joins to protect them from
moisture.
NOTE: This job is required in repairs of the engine
compartment, under the floor and other moisture entry
positions.

Three or More Times
10 mm (0.39 in.)
Tape overlapping
10 mm (0.39 in.)
Two or More Times
Finish
B±31
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
41
Wire Harness Repair Manual (RM1022E)
HINT:

Before starting the operation, thoroughly wipe dirt and
grease off the sections to be joined.

If the adhesive surfaces of two tapes come in contact
they will stick together and will not come apart, so do
not remove the backing film except when using the
tape.

Do not let oil and dust, etc. get on the tape surface.
(a)Ready about 100 mm (3.94 in.) of silicon tape (Part
No. 08231±00045) and peel off the film.
(b)Stretch the silicon tape until its width is reduced by
half.
(c)About 10 mm (0.39 in.) from the end of the sleeve,
wrap the silicon tape around the sleeve three or more
times while stretching the tape.
(d)Wrap the remaining part of the sleeve with half of the
tape overlapping at each turn.
(e)Firmly wrap the tape two times or more about 10 mm
(0.39 in.) from the other end of the sleeve, then wrap
the tape back towards the start again and firmly finish
winding the tape around the center of the sleeve.