Lexus ES300 (2002 year). Manual - part 237

Bad Example:

Terminal in Short
Position

Terminal
Locking
Clip

[Case 1]

Full Lock Position

[Case 2]

Full Lock
Position

B–37

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

47

Wire Harness Repair Manual (RM1022E)

(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,
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.

Temporary Lock Position

Full Lock Position

Terminal Retainer

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–38

48

Wire Harness Repair Manual (RM1022E)

Type C (For 0.64 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 terminal lance 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 terminal lance 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.

The connector is fitted with a terminal retainer, return
it to the full lock position.

Type D (For 0.64 Splash Proof Type Connector)

(a)

Verify that the terminal retainer is at unlocked
position.

Upper lock

Lower lock

Rear Holder

Housing rear end

Rear Holder

B–39

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

49

Wire Harness Repair Manual (RM1022E)

(b)

Verify that Rear Holder is at unlocked position.

NOTICE:
If Rear holder or wire seal has been removed, replace
it with new one.

(c)

Insert the terminal fully into the housing until it is
locked.

HINT:

The terminal has a longer insertion stroke than

conventional ones.

(d)

Set Rear holder to locked position.
Push Rear holder in the direction of arrow until it is
locked.

(e)

Verify that Rear holder is at the specified position.
The rear end of Rear holder is flush with the rear end
of Housing.

Lock check position, upper

Lock normal engagement position

Incomplete lock engagement

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–40

50

Wire Harness Repair Manual (RM1022E)

Verify that the lock (upper side) is at the specified position
under locked status.