Lexus ES300 (2002 year). Manual - part 235

Small (Red)

Medium (Blue)

Large (Yellow)

Good Example

Two Stripped Wires

Sleeve (Blue)

Bad Example

Pressure–Contact
Section

Wire in
Short Position

Wire Bend

Special Tool

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Wire Harness Repair Manual (RM1022E)

(b)

Use the table to determine proper sleeve size

Part Number

Nominal 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 Marks

Crimping
Tool

”CLOSE HERE”

Contact

”INS” Position

10 mm (0.39 in.)

Three or More Times

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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 ”Part No. 169060” 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 ”CLOSE HERE”.

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 ”INS” 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

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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.

Special Tool

Locking clip

Special Tool

Terminal Lance

”Insulation Displacement Connector”

Terminal Lance

”0.64 Type”

Special Tool

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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.