Lexus ES300 (2002 year). Manual - part 234

Tool Hole

Terminal Lance

Special
Tool

Special
Tool

Tool Hole

Special 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 Direction

1

°

 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
Harness

Supplied lead
with New Terminal

A

A

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 Evenly

Calipers

Wire 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 ”nominal size” of wire

Nominal size=

3.14 x (Diameter of wire lead)

2

4