Toyota RM06H0E engine. Manual - part 3

Example:

Back of the 
Connector Body

P/N 90980–10854

B–5

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

21

Wire Harness Repair Manual

NOTICE:

D

When the terminal used is gold plated, be sure to
replace it with a gold plated terminal when marking
repairs.

D

Do not use male and female terminals which are
made of different materials from each other.

2.

Connector Body

(a)

Identify the part number of the corresponding
terminal with wire according to the above–mentioned
1.

(b)

Identify the part number of the connector body by
picking out the correct one from the illustrations
according to the number of terminals and the shape.

HINT:
(a)

If you can find no connector which matches the type
you require, pick out male and female connector
bodies as a set which have more terminals than you
require.

For the combined terminal type connector body, pick
out and appropriate connector body for each terminal
being used.

Example:
When two types of terminal are used in one connector
body, pick out a male and female for two different
connector bodies.

(b)

The part number has been stamped on the back of
the connector body. (This will continue to be done to
new types of connector.)

B

Hole Plug

Connector Body

Terminal 
Packing

Small (Red)

Large (Yellow)

Medium (Blue)

Medium (Blue)

1.0–2.0 mm

Large (Yellow)

3.0–5.0 mm

Wire Outside

Diameter

Sleeve Size

(Color)

Small (Red)

0.2–1.0 mm

Wire Outside Diameter

Insulation

Calipers

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–6

22

Wire Harness Repair Manual

3.

Hole Plug/Terminal Packing

(a)

Identify the part number of the appropriate terminal
with wire/connector body from the illustrations of
waterproof type connector according to the
above–mentioned 1 and 2.

(b)

Identify the part number of the hole plug/terminal
packing from the corresponding illustration.

4.

Sleeve

When connecting two wires using a sleeve, select the
sleeve according to the following table.

(a)

When size is based on the outside diameter of the
wire.

B

∗

 Nominal size of the wire

Wire Outside Diameter

Nominal Size

Insulation

Stripped Wire Harness Section

B–7

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

23

Wire Harness Repair Manual

(b)

When size is based on the nominal size of the wire.

Sleeve size
S : Small (Red)
M : Medium (Blue)
L : Large (Yellow)

HINT:

To calculate the ”Nominal Size” of the wire.

Nominal size =

3.14 x (Diameter of stripped wire harness)

2

4

HINT:

Outside Diameter and Nominal Size

B

Example:

Press Down

Press Down

Pull Up

Pull Up

Reference:

(mm)

for 1.0III KITCUT Type

1

1~2

Reference:

(mm)

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–8

24

Wire Harness Repair Manual

Step 2.

Disconnect the Terminal from the Connector.

1.

Disconnect Connector

To pull apart the connectors, pull on the connector itself,
not the wire harness.

HINT:

Check to see what kind of connector you are

disconnecting before pulling apart.
Press down type is mainly used.

2.

Prepare the Special Tool

HINT:

To remove the terminal from the connector, please

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

B

Example:

Up

Tool

Terminal Retainer

B–9

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

25

Wire Harness Repair Manual

3.

Disengage the double locking device or terminal
retainer.

(a)

Locking device must be disengaged before the
terminal locking clip can be released and the terminal
removed from the connector.

(b)

Use a special tool or the terminal pick to unlock the
double locking device.

NOTICE:
Do not remove the terminal retainer from connector
body.

Raise Up

Terminal Retainer

Special
Tool

Terminal Retainer

[Retainer at Full Lock Position]

Stopper

[Retainer at Temporary Lock Position]

Terminal
Retainer

Good

Bad

Good

Bad

[Male]

[Female]

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–10

26

Wire Harness Repair Manual

Type A (For 0.64II, 0.64III, 1.0II, 1.8, 2.3II, 4.8 and 8.0 of
Non–Waterproof Type Connector)

(1)

Using the special tool, raise the retainer up to the
temporary lock position.

HINT:

The needle insertion position varies according to

the connector’s shape (number of terminals, etc.), so
check the position before inserting it.

B

Special Tool

Access Hole

Tab

Open

∗

∗

∗

∗

Open

[Male]

[Female]

∗

 Double Locking Device.

Retainer

Side Lock

B–11

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

27

Wire Harness Repair Manual

Type B (For 1.8, 1.0 and TLC of Non–Waterproof Type
Connector)

(1)

Press the special tool at a 45

°

 angle into the locking

lug access hole as shown.

Raise the double locking device up as far as possible.

(2)

Remove the special tool and open the double locking
device

NOTICE:
TLC housing is not be reusable. Please replace it with
the new one after replacement of the terminal.

Type C (For TNS, FTC Type Connector)

(1)

Widen the side lock part of the retainer from side to
side using the special tool.

B

Special tool

Lock

∗

∗

∗

∗

∗

 Double Locking Device.

Special Tool

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–12

28

Wire Harness Repair Manual

(2)

Inset the special tool into the chink between the
retainer and the terminal itself. Then pry it to the
direction of the arrow shown in the illustration and
push the retainer up to release the lock.

NOTICE:

D

Do not insert the special tool too much. It may cause
damage on the fit section of the terminal and the
wire harness.

D

TNS housing is not reusable. Please replace it with
the new one after replacement of the terminal.

Type D (For 1.3 of Non–Waterproof Type Connector)

[Case 1]
(1)

Use the special tool to unlock the double locking
device.