ad blue TOYOTA SUPRA 1995 Service Owner's Manual

Terminal (Female)
Housing (Female)
Housing (Male)
Terminal (Male)
Wire
Harness
(W/H)Electric Wire
Terminal
Housing
Fuse
Other J/B
(Junction Block)
R/B
(Relay Block)
Insulator
Copper Wires
(Conductor)
B = Black W = White
L = Blue BR = Brown
V = Violet SB = Sky Blue
R = Red G = Green
P = Pink LG = Light Green
Y = Yellow GR = Gray
O = Orange
A±2
INTRODUCTION±GENERAL INFORMATION
3
Wire Harness Repair Manual (RM1022E)
What is Wire Harness?
The wire harness (W/H) is systems of electric wires for
automobiles to connect all the electronics parts in
automobile electrically and work them. As more electronics
parts are introduced in automobiles recently, the electric
wires used for the wire harness are increasing in number
and the structure is becoming more complicated. As a
result of that, there are hundreds of connectors, which is
the parts which connects wires mechanically and
electrically, in one vehicle. Therefore, numbers of the
connector terminal (Terminal) or the connector housing
(Housing) are designed to meet many kinds of uses of
circuits. Various components have been improved to
ensure the product reliability or realize a wider space in the
vehicles.
Wire Harness Components
Wire harness mainly consists of wires, terminals, or
housings.
There are various components are designed for many
parts of vehicles, such as one with high heat±resistance,
water±resistance, or bending ability, ones have different
current capacities, or ones are hardly influenced by
electromagnetic noise.
Electric Wire
The electric wires used for the wire harness consists of the
conductor made from numbers of twisted mild copper wire
with a diameter of less than 0.5 mm and the insulator
surrounding the conductor.
The insulator is generally made from vinyl chloride and
covers the conductor with even thickness. The insulators
are color±coded in order to distinguish each wire. The base
colors or the stripe patterns is used to make difference
between insulators. Each color of wires is indicated by the
abbreviation in the repair manual and the electrical wiring
diagram.
A

LY±
(Blue) (Yellow) Example: L±Y
Tab width
1.3 mm
Rubber
Plug
Rubber Ring
Housing Lance
Type
Terminal Lance
Type
INTRODUCTION±GENERAL INFORMATION
A±3
4
Wire Harness Repair Manual (RM1022E)
The first letter indicates the basic wire color and the second
letter indicates the color of the stripe.
Terminal and housing
Terminal connects wires and housing insulates connecting
parts.
There are the male terminal and the female terminal. The
types of terminals are decided by tab width of male
terminal. And the terminal with the rubber plug or the
rubber ring is used in the part, such as the engine
compartment, which become wet. For the circuit with slight
current at EFI system or ABS system, the gold±plated
terminal is introduced for ensuring reliabilities.
As the number of the circuit is increasing recently, there are
new types of parts introduced. For example, there is the
hybrid type housing, which is a combination of terminals
with different tab width, such as the power source terminal
or the signal terminal. Also, new type of connector such as
the double lock housing, which is designed with the
retainer in addition to the lance to prevent terminal from
slipping off, is available. The new type of connectors are
produced to realize higher product reliabilities and utilized
widely recently. The major characteristics of these new
connectors are shown in the table 1.
There are two types of lances: housing lance, which is
inside the housing and terminal lance, which is inside the
terminal.A

Reference:
(mm)
B±1
TERMINAL AND CONNECTOR REPAIR±PREPARATORY ITEMS
11
Wire Harness Repair Manual (RM1022E)
PREPARATORY ITEMS
Crimping tool AMP Part No. 169060For caulking
press sleeves
ToolSpecial tool Refer to the following illustrationTo remove the
terminal
SST 09991±00500
To remove the
0.64 connector
terminal
GaugeCaliper 0±150 mm
To measure the
diameter of the
core
Others
82999±12010 (Red)
Press sleeve 82999±12020 (Blue)
82999±12030 (Yellow)
To connect wires
Others
Silicon tape 08231±00045
To waterproof
the connected
section
Special Tool
HINT: To remove the terminal from the connector, please
construct and use the special tool or like object shown on
the left.
Preparation of the SST to release the 0.64 connector terminal.
SST 09991±00500
HINT:
This is a SST for releasing terminals from 0.64 connectors.
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
B±6
16
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
B±7
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
17
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

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.

F±1
TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE
Wire Harness Repair Manual (RM1022E)
379
Repair Wire (Waterproof Type)
Type1.0II
MaleFemale
Sleeve : Medium (Blue)
P/N82998±24060
Type1.0III
MaleFemale
Sleeve : Medium (Blue)Sleeve : Medium (Blue)
P/N82998±1271082998±12720
82998±12730*
Type1.3
MaleFemale
Sleeve : Medium (Blue)Sleeve : Medium (Blue)
P/N82998±1263082998±12650
F

TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE
F±2
380
Wire Harness Repair Manual (RM1022E)
Repair Wire (Waterproof Type)
Type1.8
MaleFemale
Sleeve : Medium (Blue)
P/N82998±12620
Type2.3
MaleFemale
Sleeve : Medium (Blue)Sleeve : Medium (Blue)
P/N82998±12260
82998±24070*82998±12270(160mm) 82998±12600(500mm)
82998±24080*
Type2.3II (6mm Pitch Type)
MaleFemale
Sleeve : Medium (Blue) or Large (Yellow)Sleeve : Medium (Blue) or Large (Yellow)
P/N82998±12430
82998±12450*82998±12440(160mm) 82998±12590(500mm)
82998±12460*
F

F±3
TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE
Wire Harness Repair Manual (RM1022E)
381
Repair Wire (Waterproof Type)
Type2.3II (5mm Pitch Type)
MaleFemale
Sleeve : Medium (Blue) or Large (Yellow)
P/N82998±12790
82998±12780*
Type4.8
MaleFemale
Sleeve : Large (Yellow)Sleeve : Large (Yellow)
P/N82998±1247082998±12480
Type6.3
MaleFemale
Sleeve : Large (Yellow)
P/N82998±12540
F

TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE
F±4
382
Wire Harness Repair Manual (RM1022E)
Repair Wire (Waterproof Type)
Type6.3II
MaleFemale
Sleeve : Medium (Blue)
P/N82998±24160
Type8.0
MaleFemale
Sleeve : Large (Yellow)Sleeve : Large (Yellow)
P/N82998±1249082998±12500
TypeHEAD LAMP
MaleFemale
Sleeve : Medium (Blue) or Large (Yellow)
P/N82998±24150(160mm) 82998±24190(500mm)
F