Lexus ES300 (2002 year). Manual - part 236

Wire

”Click”

”Click”

”0.64 IDC Type”

”Click”

”Insulation 
Displacement 
Connector”

Good Example:

Bad Example:

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TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

43

Wire Harness Repair Manual (RM1022E)

1.

Push the Terminal into the Connector until you
hear a ”click”.

NOTE: Not all terminals will give and audible ”click”.

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

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44

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

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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 Clip

Terminal Retainer
at Temporary Lock 
Position

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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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)

”For Case 1”
Push the terminal retainer in to the full lock position.

”For Case 2”
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.