Lexus ES300 (2002 year). Manual - part 233

Good

Bad

Special Tool

Lock

Special
Tool

Special Tool

Lock

Special Tool

Lock Housing

Upper
Housing

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TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Manual (RM1022E)

Type L (0.64 of Insulation Displacement Connector (IDC)
Type)

(1)

Remove the Lower Housing

Using a special tool, release the lock and remove the lower
housing.

NOTICE:

Do not apply too much force to the lock arm.

Mark the upper housing and lower housing to
prevent mistakes when putting them together.

(2)

Remove the Upper Housing

Using a special tool, release the lock and remove the upper
housing from the lock housing.

NOTICE:

Do not apply too much force to the lock arm.

Mark the upper housing and lower housing to
prevent mistakes when putting them together.

Type M (0.64 of Splash Proof Connector)

(1)

Release Terminal retainer.

Insert Special Tool at the location shown in the figure
left.

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

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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

”Waterproof Type”

Special
Tool

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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

”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

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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.