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Toyota RM06H0E engine. Manual - part 2

Equal Amperage Rating

Puller

A–9

INTRODUCTION–CIRCUIT PROTECTION

Wire Harness Repair Manual

REPLACEMENT OF FUSE AND FUSIBLE LINK

HINT:

If replacing the fuse or fusible link, be sure to

replace it with a fuse or fusible link with an equal amperage
rating.

NOTICE:
1.

Turn off all electrical components and the ignition
switch before replacing a fuse or fusible link. Do
not exceed the fuse or fusible link amperage rating.

Always use a fuse puller for removing and
inserting a fuse. Remove and insert straight in and
out without twisting. Twisting could force open the
terminals too much, resulting in a bad connection.

If a fuse or fusible link continues to blow, a short circuit is
indicated. The system must be checked by a qualified
technician.

HINT:

The puller is located at Junction Block No.2.

memo

Wire Harness Repair Manual

TERMINAL AND CONNECTOR REPAIR

PREPARATORY ITEMS

B–1

. . . . . . . . . . . . . . . . . . . .

CONNECTOR REPAIR

B–2

. . . . . . . . . . . . . . . . . . . . .

TERMINAL REPLACEMENT

B–3

. . . . . . . . . . . . . . . .

HOW TO INSTALL AND REMOVE

SPECIAL CONNECTORS

B–47

. . . . . . . . . . . . . . . . .

Wire Harness Repair Manual

Reference:

(mm)

B–1

TERMINAL AND CONNECTOR REPAIR–PREPARATORY ITEMS

Wire Harness Repair Manual

PREPARATORY ITEMS

Tool

Crimping tool

AMP Part No. 169060

For caulking press
sleeves

Tool

Special tool

Refer to the following illustration

To remove the
terminal

Tool

SST

09991–00500

To remove the 0.64
connector terminal

SST

09992–01030

To remove the 0.64 II
connector terminal

Gauge

Caliper

0–150 mm

To measure the
diameter of the core

Others

82999–12010 (Red)

Press sleeve

82999–12020 (Blue)
82999–12030 (Yellow)

To connect wires

Silicon tape

08231–00045

To waterproof the
connected section

Special Tool

HINT:

To remove the terminal from the connector, please

construct and use the special tool or like object shown on
the left.

Preparation of the SST to release the 0

.64

connector

terminal.

SST 09991-00500

HINT:
This is a SST for releasing terminals from 0.64 connectors.

Preparation of the SST to release the 0

.64 II

connector

terminal.

SST 0999

-0

1030

HINT:
This is a SST for releasing terminals from 0.64 II
connectors.

TERMINAL AND CONNECTOR REPAIR–CONNECTOR REPAIR

B–2

Wire Harness Repair Manual

CONNECTOR REPAIR

The repair parts now in supply are limited to those connectors having common shapes and terminal
cavity numbers. Therefore, when there is no available replacement connector of the same shape or
terminal cavity number, please use one of the alternative methods described below. Make sure that the
terminals are placed in the original order in the connector cavities, if possible, to aid in future diagnosis.

1. When a connector with a different number of terminals than the original part is used, select a connector

having more terminal cavities than required, and replace both the male and female connector parts.

EXAMPLE:

You need a connector with six terminals, but the only replacement available is a connector

with eight terminal cavities. Replace both the male and female connector parts with the eight terminal part,
transferring the terminals from the old connectors to the new connectors.

2. When several different type terminals are used in one connector, select an appropriate male and female

connector part for each terminal type used, and replace both male and female connector parts.

EXAMPLE:

You need to replace a connector that has two different types of terminals in one connector.

Replace the original connector with two new connectors, one connector for one type of terminal, another
connector for the other type of terminal.

3. When a different shape of connector is used, first select from available parts a connector with the

appropriate number of terminal cavities, and one that uses terminals of the same size as, or larger than,
the terminal size in the vehicle. The wire lead on the replacement terminal must also be the same size as,
or larger than, the nominal size of the wire in the vehicle. (”Nominal” size may be found by looking at the
illustrations in the section F or by direct measurement across the diameter of the insulation). Replace all
existing terminals with the new terminals, then insert the terminals into the new connector.

EXAMPLE:

You need to replace a connector that is round and has six terminal cavities. The only round

replacement connector has three terminal cavities. You would select a replacement connector that has
six or more terminal cavities and is not round, then select terminals that will fit the new connector. Replace
the existing terminals, then insert them into the new connector and join the connector together.

B–3

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Manual

TERMINAL REPLACEMENT

These steps must be followed when replacing a terminal.

Step 1. Identify the connector and the terminal type.

Step 2. Disconnect the terminal from the connector.

Step 3. Replace the terminal.

Step 4. Install the terminal into the connector.

Type

Male

Female

F-7

040III IDC

040III

Repair Wire (Non-Waterproof Type)

TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE

040IV

Type

P/N

82998-12670
82998-12680*

82998-12690
82998-12700*

82998-12660

82998-12640

82998-12740

Sleeve : Medium (Blue)

A = 1.0mm
D = 2.0mm
E = 0.5

A = 1.8mm
D = 2.0mm
E = 0.5

A = 1.0mm
D = 2.0mm
E = 0.5

A = 1.8mm
D = 2.0mm
E = 0.5

A = 1.8mm
D = 2.1mm
E = 1.25

82998-12690

82998-12700*

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–4

Wire Harness Repair Manual

Step 1.

Identify the connector and the terminal type.

Confirm whether the connector you require is the non–waterproof, waterproof or combined terminal type
connector from the pictures provided in the following charts.

Connector

Description

Non–Waterproof Type

Those connectors which are not of the
waterproof or combined terminal type.

Waterproof Type

Waterproof material (hole plug or terminal
packing) is provided on the terminal/connector
body.

Combined Terminal Type

Terminals of different shape/size are located in
one connector.

Terminal with Wire

Identify the part number of the terminal with wire by picking
out the corresponding illustration from the pictures
provided on the following charts.

HINT:

In some of the illustrations, there are two part

numbers for the same illustration of terminal with wire,
because although the shapes of the terminals are
completely the same, there is a difference in with /without
gold–plating (gilded).

Remark:

The length of the wire connected to the

terminal is approximately 150 mm.

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