FOREWORD - Toyota-Tech.eu

1 E2007 All rights reserved. This book may not bereproduced or copied, in whole or in part, without thewritten permission of Toyota Motor Printing : Jul. 06, 2007 01 070706 00 FOREWORDThis manual has been prepared for use whenperforming terminal repairs, wire repairs, or connectorrepairs on step by step section on connector repair andterminal repair is is a section of charts with terminal and connectorillustrations, part numbers, and notes on using this guide, a satisfactory repair of the wiringharness and connectors in Toyota vehicles will be easyto information in this manual is based on the latestproduct information at the time of publication. However,specifications and procedures are subject to changewithout Harness Repair Manual (RM1022E)1 Section CodeINTRODUCTION.

2 ATERMINAL AND CONNECTOR REPAIR .. BTABLE OF HOUSING CROSS SECTION .. CTABLE OF HOUSING SHAPE .. DHOUSING PART NUMBER LIST .. ETABLE OF REPAIR WIRE, TERMINAL PACKING,FHOLE PLUG AND PRESS SLEEVE .. FAPPENDIX .. GTABLE OF CONTENTSWire Harness Repair Manual (RM1022E)2 Wire Harness Repair Manual (RM1022E)3 INTRODUCTIONGENERAL INFORMATIONA 1.. TERMINAL TYPE NUMBER NAMEA 1.. WHAT IS WIRE HARNESS?A 2.. WIRE HARNESS COMPONENTSA 2.. electric WIREA 3.. TERMINAL AND HOUSINGA 3.. HOW TO PERFORM FOR SYSTEM INSPECTIONA 5.. CIRCUIT PROTECTIONA 8.. A4 Wire Harness Repair Manual (RM1022E)ATab mmA 1 INTRODUCTION GENERAL INFORMATION5 Wire Harness Repair Manual (RM1022E)GENERAL INFORMATIONThis manual provides instruction in the following repairs:DHow to Inspect for System InspectionDCircuit ProtectionDTerminal and Connector Repair ProcedureNOTICE:When inspecting or repairing the SRS AIRBAG, be sure to carefully read the precautionaryinstructions and procedure in the Repair Manual for the applicable any electrical repair is made, always test the circuit by operating the devices in the circuit.

3 Thisconfirms not only that the repair is correct, but also that the cause of the complaint was type number nameThe terminal type number naming system has changed:the metric system will be used in place of the inch be more specific, male tab width in millimeters will beused as terminal type number from now on in place ofmale tab width in inches which has been in use so is a table of comparison:Old terminal type No.(inch)New terminal type No.(mm)025 (II, III, IV) (II, III, IV)050 (II) (II)090 (II) (II)110 (II) (II)305 those connectors which are not shown above, theterminal type numbers remain (Female)Housing (Female)Housing (Male)Terminal (Male)WireHarness(W/H) electric WireTerminalHousingFuseOtherJ/B(Junction Block)R/B(Relay Block)InsulatorCopper Wires(Conductor)B = BlackW= WhiteL = BlueBR = BrownV = VioletSB = Sky BlueR = RedG= GreenP = PinkLG = Light GreenY = YellowGR = GrayO = OrangeINTRODUCTION GENERAL INFORMATIONA 26 Wire Harness Repair Manual (RM1022E)What is Wire Harness?

4 The wire harness (W/H) is systems of electric wires forautomobiles to connect all the electronics parts inautomobile electrically and work them. As more electronicsparts are introduced in automobiles recently, the electricwires used for the wire harness are increasing in numberand the structure is becoming more complicated. As aresult of that, there are hundreds of connectors, which isthe parts which connects wires mechanically andelectrically, in one vehicle . Therefore, numbers of theconnector terminal (Terminal) or the connector housing(Housing) are designed to meet many kinds of uses ofcircuits. Various components have been improved toensure the product reliability or realize a wider space in Harness ComponentsWire harness mainly consists of wires, terminals, are various components are designed for manyparts of vehicles, such as one with high heat resistance,water resistance, or bending ability, ones have differentcurrent capacities, or ones are hardly influenced byelectromagnetic WireThe electric wires used for the wire harness consists of theconductor made from numbers of twisted mild copper wirewith a diameter of less than mm and the insulatorsurrounding the insulator is generally made from vinyl chloride andcovers the conductor with even thickness.

5 The insulatorsare color coded in order to distinguish each wire. The basecolors or the stripe patterns is used to make differencebetween insulators. Each color of wires is indicated by theabbreviation in the repair manual and the electrical (Blue)(Yellow)Example: L YTab mmRubber PlugRubber RingHousing LanceTypeTerminal LanceTypeA 3 INTRODUCTION GENERAL INFORMATION7 Wire Harness Repair Manual (RM1022E)The first letter indicates the basic wire color and the secondletter indicates the color of the and housingTerminal connects wires and housing insulates are the male terminal and the female terminal. Thetypes of terminals are decided by tab width of maleterminal. And the terminal with the rubber plug or therubber ring is used in the part, such as the enginecompartment, which become wet.

6 For the circuit with slightcurrent at EFI system or ABS system, the gold platedterminal is introduced for ensuring the number of the circuit is increasing recently, there arenew types of parts introduced. For example, there is thehybrid type housing, which is a combination of terminalswith different tab width, such as the power source terminalor the signal terminal. Also, new type of connector such asthe double lock housing, which is designed with theretainer in addition to the lance to prevent terminal fromslipping off, is available. The new type of connectors areproduced to realize higher product reliabilities and utilizedwidely recently. The major characteristics of these newconnectors are shown in the table are two types of lances: housing lance, which isinside the housing and terminal lance, which is inside GENERAL INFORMATIONA 48 Wire Harness Repair Manual (RM1022E)Table 1 : Characteristics of the new types of connector (Improvement)Characteristics (Improvement)NoteRetainer (Double Lock)Lance (Primary Lock)HousingTerminal1.

7 Double LockIf terminal is not inserted tohousing correctly, the retailerdoes not Extension of HousingExtensionShorteningHousingTermina lThis is to prevent deformation ofthe terminal when it is Change of Contact Structure andIntroduction of Box Shaped StructureExpansion of contact sectionStabilization of contact pressure4. Change of Locking ShapeRibs are addedThis improves the close fit oflocking and you can hear theclick sound and feel that theconnector is Ignition SWIG TerminalFuseRelaySW2 SolenoidVoltmeter[A][B][C]SW1 OhmmeterSWA 5 INTRODUCTION HOW TO PERFORM FOR SYSTEM INSPECTION9 Wire Harness Repair Manual (RM1022E)HOW TO PERFORM FOR SYSTEM INSPECTIONThis inspection procedure is a simple troubleshooting which should be carried out on the vehicle duringsystem operation and is based on the assumption of system component troubleAlways inspect the trouble taking the following items into consideration:DGround point faultDOpen or short circuit of the wire harnessDConnector or terminal connection faultDFuse or fusible link faultNOTICE.

8 DThis is an on vehicle inspection during system , inspect the trouble with due regard for connecting the battery directly, be careful not to cause a short circuit, and select the Check(a) Establish conditions in which voltage is present at thecheck :[A] Ignition SW on[B] Ignition SW and SW 1 on[C] Ignition SW, SW 1 and Relay on (SW 2 off)(b) Using a voltmeter, connect the negative ( ) lead to agood ground point or negative ( ) battery terminaland the positive (+) lead to the connector orcomponent terminal. This check can be done with atest bulb instead of a and Resistance Check(a) Disconnect the battery terminal or wire so there is novoltage between the check points.(b) Contact the two leads of an ohmmeter to each of thecheck TypeAnalog TypeBulbOhmmeterINTRODUCTION HOW TO PERFORM FOR SYSTEM INSPECTIONA 610 Wire Harness Repair Manual (RM1022E)If the circuit has diodes, reverse the two leads and touching the negative ( ) lead to the diode positive(+) side and the positive (+) lead to the negative ( ) side,there should be continuity.

9 When touching the two leads inreverse, there should be no :Specifications may vary depending on the type oftester, so refer to the tester s instruction manual beforeperforming the LED (Light Emitting Diode) in the same manner asthat for :DUse a tester with a power source of 3V or greater toovercome the circuit a suitable tester is not available, apply batteryvoltage and check that the LED lights up.(c)Use a volt/ohmmeter with high impedance (10k /Vminimum) for troubleshooting of the electrical Check(a) Remove the bulb.(b) There should be continuity between the respectiveterminals of the bulb together with a certain amountof resistance.(c)Apply the two leads of the ohmmeter to each of theterminals.(d) Apply battery voltage and check that the bulb light CaseTest BulbShort [A]SW1 Short [B]RelayLightShort [C]SW2 SolenoidDisconnectDisconnectDisconnectTo Ignition SWIG TerminalA 7 INTRODUCTION HOW TO PERFORM FOR SYSTEM INSPECTION11 Wire Harness Repair Manual (RM1022E) a Short Circuit(a) Remove the blown fuse and eliminate all loads fromthe fuse.

10 (b) Connect a test bulb in place of the fuse.(c)Establish conditions in which the test bulb comes :[A] Ignition SW on[B] Ignition SW and SW 1 on[C] Ignition SW, SW 1 and Relay on (Connect the Relay)and SW 2 off (or disconnect SW 2)(d) Disconnect and reconnect the connectors whilewatching the test bulb. The short lies between theconnector where the test bulb stays lit and theconnector where the bulb goes out.(e) Find the exact location of the short by lightly shakingthe problem wire along the :(a) Do not open the cover or the case of the ECUunless absolutely necessary. (If the IC terminalsare touched, the IC may be destroyed by staticelectricity.)(b) When replacing the internal mechanism (ECUpart) of the digital meter, be careful that no part ofyour body or clothing comes in contact with theterminals of leads from the IC, etc.