Toyota RM06H0E engine. Manual - part 56

G–1

APPENDIX–WIRE HARNESS REPAIR KIT WITH CASE

Wire Harness Repair Manual

445

WIRE HARNESS REPAIR KIT WITH CASE (REFERENCE ONLY)

We would like to recommend to you use of the ”Wire Harness Repair Kit with the Case”
according to your after service market demand.

Example:

[portable type]

[stationary type]

Remark:

This kind of kit is not available from Toyota Motor Corporation.

APPENDIX–REPORTING OF WIRE HARNESS PROBLEM

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446

Wire Harness Repair Manual

REPORTING OF WIRE HARNESS PROBLEM

It is more difficult to understand the cause of wire harness problems and to make
production improvements, due to the number of wire harness routings and connectors and
their wide scope of use.
The position of the problem occurrence and the problem cause will be very clear if you
proceed with wire harness/connector repairs.
We request that when you perform repairs, you fill in the attached ”WIRE
HARNESS/CONNECTOR PROBLEM CHECK SHEET” and send it to your distributor.
Toyota Motor Corporation will be able to make production improvements more quickly and
surely based on the results of the above mentioned reports (Check Sheets).

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APPENDIX–REPORTING OF WIRE HARNESS PROBLEM

Wire Harness Repair Manual

447

WIRE HARNESS/CONNECTOR PROBLEM CHECK SHEET

Please use the TOYOTA ELECTRICAL WIRING DIAGRAM (EWD) manual to answer this questio-
nnaire accurately.

Dealer Name

Please fill in the required information in the brackets and check the appropriate box.

Full Model Code

P/D

Customer Complaint:

CONNECTOR PROBLEM:

Electrical Component with Problem:

Others (Eg.Rattle,Noise etc. - Please proceed to "Box B" on next page.)

Short

page 1/3

Symptom:

Open circuit

EWD page ( )

CONNECTOR NO.( )

WIRE COLOR ( )

PIN No. ( )

Male

TERMINAL MISSING (Terminal Coming off)

TERMINAL BROKEN

TERMINAL BENT (Male)

TERMINAL EXPANDED (Female)

WIRE POORLY CRIMPED AT TERMINAL

CORROSION, RUST, MOISTURE

POOR CONTACT

NON-WATERPROOF TYPE

BROKEN LOCKING CLIP OF CONNECTOR

TERMINAL LOCKING CLIP MISSING

TERMINAL RETAINER BROKEN

SECONDARY LOCKING PLATE MISSING

OTHERS; ( )

WATERPROOF TYPE

SEAL PACKING

TERMINAL PACKING

OTHERS ( )

Female

Moisture

Please refer to Fig. 1

Intermittent operation

Condition:

km-reading/Mileage

Dealer Code

Frame No.

Date of Problem

Inoperative

Others

TERMINAL

WATER ENTERING FROM:

WIRE HARNESS

UNCLEAR, OTHERS

Male

NOT CONNECTED/HALF CONNECTED

BROKEN CONNECTOR

BROKEN LOCKING CLIP OF CONNECTOR

OTHERS ( )

CONNECTOR BODY

Female

Male

Seal Packing

Used for
All Models

Used from
'89 CRESSIDA

Mainly
Used for
Engine ECU

Fig.1

Terminal Packing

Terminal Locking Clip

Terminal Retainer

Secondary Locking
Device

Terminal Pin

APPENDIX–REPORTING OF WIRE HARNESS PROBLEM

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448

Wire Harness Repair Manual

WIRE HARNESS PROBLEM:

page 2/3

Please fill in the required information in the brackets and check the appropriate box.

Name of the other part which
causef the short/open of wire

BODY

Name

YES

CONDUIT TUBE

LOOSE SET BOLT

CORROSION, RUST

OTHERS ( )

VINYL TUBE

PINCHED

SHORT

OPEN

Problem occurred between

E.W.D Page ( )

*CONNECTOR NO.A ( )

PIN NO. ( )

and

WIRE COLOR ( )

* The problem indicated below occurred at a distance
of ( mm) from connector A ( )

INTERFERENCE/ABRATION

MOISTURE

CUT WIRE

SPLICE POINT

OTHRES;

BATTERY

STARTER

EARTH TERMINAL

POOR CONTACT OF
RING TYPE TERMINAL

POWER SOURCE TERMINAL

ALTERNATOR

CORROSION, RUST

OTHERS;

VINYL TAPE

VINYL SHEET

OTHERS ( )

INSULATION:

PART

OTHERS

If you checked the "Others" box in the "Symptom" section on page 3-1, please describe:

Symptom:

Related Wire Harness or Connector;

Name or Part NO.:

Location:

Note:

Box B

If possible, attach an illustration or photo to show the part causing the short or open, and
the position of the wire and the other part.
This will help to make the cause of the problem clear and help us to take prompt action.

Condition:

CONNECTOR NO.B ( )

PIN NO. ( )

WIRE COLOR ( )

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APPENDIX–REPORTING OF WIRE HARNESS PROBLEM

Wire Harness Repair Manual

449

C18

A16

C10

A10

A13

C19

A11

A15

C11

C12

C13

C15

C14

C17

A12

A14

C16

REPAIR:

page 3/3

CRIMPING PLIERS

SOLDER CONNECTION

REPLACE WIRE HARNESS

2. Please check one box

WIRE HARNESS TOOLS

Troubleshooting methods

PICK

WIRING DIAGRAM

VOLTMETER:

ANALOG

OTHERS ( )

REPLACE CONNECTOR OR TERMINAL

REPAIR TERMINAL

OTHERS ( )

DIGITAL

1. Please identify repair method:

3. Please attach a copy of the TOYOTA ELECTRICAL WIRING DIAGRAM for the vehicle

repaired:

Indicate the affected connector number by arrow, or circle and identify the affected wire

harness.

EXAMPLE: COROLLA (ZZE 110)

Indicate by CIRCLE

Indicate by ARROW

Condition: Engine does not start

Cause: Connector pin backed out from female connector at clutch start switch

Component: Clutch start awitch inoperation

and fill in prethesis:

APPENDIX

−P

ART NUMBER LIST

−6

Wire

Harness Repair Manual (RM1022E)

406

Waterproof Type [1]

(Cont. next page)

1.0

1.0 III

M:11863

F:11856

1.3

M:11188

M:11169

M:11063

M:11181

M:11171

M:11191

M:11173

F:11189

F:11170

F:11065

F:11182

F:11172

F:11192

F:11174

M:11064

F:11066

1.8

F:10737

F:10711

F:11062

2.3

M:10495

M:10580

M:10475

M:10650

F:10496

F:10609

F:10476

M:10592

M:10590

F:10474

F:10532

M:10575

M:10648

F:10598

F:10572

2.3 II

M:10892

M:10842

M:11486

M:11247

M:11015

M:10868

M:11078

M:10987

M:10930

M:10890

F:10893

F:10843

F:11019

F:11248

F:11207

F:11016

F:11143

F:10869

F:11077

F:10988

F:10931

F:10891

F:11231

M:11006

M:10886

M:11029

M:11272

M:11131

M:10941

M:11033

M:10890

F:11007

F:10887

F:11030

F:11273

F:11235

F:11132

F:11145

F:10942

F:11024

F:11034

F:11190

M:11270

M:10898

M:11137

M:11244

M:11027

M:11193

M:10896

F:11271

F:10899

F:11038

F:10974

F:11246

F:11245

F:11261

F:11028

F:11049

F:11194

F:10897

M:10900

M:11050

M:11295

M:11122

M:11196

F:11166

F:10901

F:11051

F:11025

F:11250

F:11245

F:11294

F:11037

F:11232

F:11197

M:11072

M:11069

M:11177

M:11289

F:11243

F:10923

F:11070

F:11068

F:11255

F:10834

F:11349

F:11178

F:11317

F:11290

M:10959

M:11073

M:11348

M:11291

F:11363

F:10947

F:11075

F:11140

F:11285

F:10845

F:11292

F:11599

F:10854

M:10948

M:11074

F:11428

F:10949

F:11075

F:11149

F:12028

F:10902

F:10943

F:11144

M:11002

M:11141

F:11252

F:11003

F:11142

F:11153

F:10919

F:11150

F:11858

M:11004

M:11155

F:11005

F:11156

F:11154

F:10981

F:11152

M:11008

M:11168

F:11009

F:11162

F:11163

F:11020

M : Male

F : Female

APPENDIX

−P

ART NUMBER LIST

−7

Wire

Harness Repair Manual (RM1022E)

407

Waterproof Type [1] (Cont’d)

1.0

F:11215

F:11214

1.0 III

1.3

M:11088

F:11698

F:11089

1.8

2.3

2.3 II

M:11086

F:11087

F:11151

M : Male

F : Female

APPENDIX

−P

ART NUMBER LIST

−8

Wire

Harness Repair Manual (RM1022E)

408

Waterproof Type [2]

4.8

M:10982

M:10927

M:10840

M:10989

F:10983

F:10928

F:10841

F:10990

M:10944

M:11035

F:11400

F:11237

F:10841

F:11036

6.3

M:10246

M:10156

M:10347

F:10247

F:10157

F:10249

7.7

M:10114

F:10115

8.0

M:10836

M:10838

F:10837

F:10839

M:11183

M:11031

F:11184

F:11032

HB3

F:11095

F:11659

HB4

F:11096

F:11660

PIN

M:11945

TLC

M:10577

F:10554

TODC

M:10240

M:10244

F:10241

F:10353

1.0 III+4.8

F:12020

F:12021

2.3+6.3

F:10686

2.3 II+4.8

M:11160

M:10749

M:10945

M:10894

M:11239

F:11161

F:10844

F:10946

F:10939

F:10895

F:11643

F:11332

M:11021

F:10940

F:11022

F:11784

M:11412

F:11413

2.3 II+6.3 II

F:11195

F:11323

2.3 II+8.0

M:11241

F:11242

4.8+8.0

M:11044

M:11138

F:11045

F:11139

M : Male

F : Female

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