TOYOTA SUPRA 1995 Service Repair Manual

Special ToolLocking clip
Special Tool Terminal Lance ºInsulation Displacement Connectorº
Terminal Lance º0.64 Typeº
Special Tool
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±32
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Wire Harness Repair Manual (RM1022E)
Step 4. Install the terminal into the connector.
HINT:
(a)Make sure the terminal is positioned correctly.
(b)Insert the terminal until the locking clip locks firmly.
(c)Insert the terminal with terminal retainer in the
temporary lock position, if equipped.
NOTE: If reusing a terminal, check that the locking clip is
still in good condition and in the proper position.
(a)If it is on the terminal and not in the proper position,
use the special tool to gently bend the locking clip
back to the original shape.
(b)Check that the other parts of the terminal are in their
original shape.
NOTICE:
Do not readjust or reuse the terminal lance of the
insulation displacement connector type terminal.
Always change the wire with the repair wire.
NOTICE:
As for 0.64 type terminal, do not adjust the terminal
lance with the special tool.
Splash Proof Type Connector
NOTICE:

Removal of the terminal from housing cavity will
cause damage to rubber plug material (the wire
seal), deteriorating waterproofing performance. Be
sure to replace the housing with a new one.

Check the withdrawn terminal for the following if
trying to use it again.

It is free of deformation and damage

It is free of adherents such as rubber plug
material (wire seal)

Replace any deformed terminal.

Wire
ºClickº
ºClickº º0.64 IDC Typeº
ºClickº ºInsulation
Displacement
Connectorº
Good Example:
Bad Example:
B±33
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (RM1022E)
1. Push the Terminal into the Connector until you
hear a ºclickº.
NOTE: Not all terminals will give and audible ºclickº.
NOTICE:

After repairing, never let only one harness stretch.

In cese that it becomes short, do over again using
the repair wire.

Terminal Retainer
Example:
Good
Bad Good
Bad
[Female]
[Male] *Terminal
In Short
Position
*Terminal
In Short
Position Double Locking
Device
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±34
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Wire Harness Repair Manual (RM1022E)
2. Double Locking Type Connector
(with terminal retainer or double locking device)
The connector is fitted with a terminal retainer, or a double
locking device, it is in the temporary lock position at insert
the terminal.
Type A (For 1.0, 1.0II, 1.3, 1.8, 2.3II 4.8 and 8.0 of
Non±Waterproof Type Connector)
(a)Insert the terminal.
HINT:
1. Make sure the terminal is positioned correctly.
2. Insert the terminal with terminal retainer in the
temporary lock position.
(b)Insert the terminal until the locking clip locks firmly.
HINT:
1. Pull the terminal back gently to check whether it is
locked correctly.
2. If it cannot be inserted easily, check the terminal and
the connector for damage.
NOTE: If the terminal to locking clip does not lock firmly,
the double locking device cannot lock or terminal retainer
does not lock at full lock position so the terminal backs out
from connector.
(c)Close terminal retainer or double locking device.
The connector is fitted with a terminal retainer, or a
double locking device, return it to the full lock position.

Full Lock Position
[Female]
Full Lock Position
[Female]
Full Lock Position
[Male]
Terminal Retainer
at Temporary
Lock Position
Terminal Locking
Clip
B±35
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (RM1022E)
Type B (For 1.8, 2.3, 2.3II, 4.8, 6.3 and 8.0 of Waterproof
Type)
(For Male Connector)
(a)Insert the terminal.
HINT:
1. Make sure the terminal is positioned correctly.
2. Insert the terminal with terminal retainer in the
temporary lock position.
(b)Insert the terminal until the locking clip locks firmly.
HINT:
1. Pull the terminal back gently to check whether it is
locked correctly.
2. If it cannot be inserted easily, check the terminal and
the connector for damage.

Bad Example:
Terminal in Short
Position
Terminal
Locking Clip
Terminal
Retainer
[Case 1]
Full Lock Position
[Case 2]
Full Lock Position
Terminal Locking ClipTerminal Retainer
at Temporary Lock
Position
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±36
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Wire Harness Repair Manual (RM1022E)
NOTE: If the terminal to locking clip does not lock firmly,
terminal retainer can not lock at full lock position so the
terminal backs out from connector.
(c)ºFor Case 1º
Push the terminal retainer in to the full lock position.
ºFor Case 2º
Raise the terminal retainer up to the full lock position.
(For Female Connector)
(a)Insert the terminal.
HINT:
1. Make sure the terminal is positioned correctly.
2. Insert the terminal with terminal retainer in the
temporary lock position.

Bad Example:
Terminal in Short
Position
Terminal
Locking
Clip
[Case 1]
Full Lock Position
[Case 2]
Full Lock
Position
B±37
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (RM1022E)
(b)Insert the terminal until the locking clip locks firmly.
HINT:
1. Pull the terminal back gently to check whether it is
locked correctly.
2. If it cannot be inserted easily, check the terminal and
the connector for damage.
NOTE: If the terminal to locking clip does not lock firmly,
terminal retainer can not lock at full lock position so the
terminal backs out from connector.
(c)ºFor Case 1º
Push the terminal retainer in to the full lock position.
ºFor Case 2º
Raise the terminal retainer up to the full lock position.

Temporary Lock Position
Full Lock Position
Terminal Retainer
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±38
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Wire Harness Repair Manual (RM1022E)
Type C (For 0.64 Type Connector)
(a)Insert the terminal.
HINT:
1. Make sure the terminal is positioned correctly.
2. Insert the terminal with terminal retainer in the
temporary lock position.
(b)Insert the terminal until the terminal lance locks firmly.
HINT:
1. Pull the terminal back gently to check whether it is
locked correctly.
2. If it cannot be inserted easily, check the terminal and
the connector for damage.
NOTE: If the terminal to terminal lance does not lock
firmly, the double locking device cannot lock or terminal
retainer does not lock at full lock position so the terminal
backs out from connector.
(c)Close terminal retainer.
The connector is fitted with a terminal retainer, return
it to the full lock position.
Type D (For 0.64 Splash Proof Type Connector)
(a)Verify that the terminal retainer is at unlocked
position.

Upper lock
Lower lock
Rear Holder
Housing rear endRear Holder
B±39
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
49
Wire Harness Repair Manual (RM1022E)
(b)Verify that Rear Holder is at unlocked position.
NOTICE:
If Rear holder or wire seal has been removed, replace
it with new one.
(c)Insert the terminal fully into the housing until it is
locked.
HINT: The terminal has a longer insertion stroke than
conventional ones.
(d)Set Rear holder to locked position.
Push Rear holder in the direction of arrow until it is
locked.
(e)Verify that Rear holder is at the specified position.
The rear end of Rear holder is flush with the rear end
of Housing.

Lock check position, upper
Lock normal engagement position
Incomplete lock engagement
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±40
50
Wire Harness Repair Manual (RM1022E)
Verify that the lock (upper side) is at the specified position
under locked status.

Lock normal engagement position
Incomplete lock engagement Lock check position, lower
Insert Special Tool
Special Tool
hole
(U shaped)
B±41
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
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Wire Harness Repair Manual (RM1022E)
Verify that the lock (lower side) is at the specified position
under the locked status.
(f)Set Terminal retainer to Lock position.
Insert Special tool into the hole specified in the left
and push Terminal retainer.