Page 1449 of 2389
Special Tool
Lock
Special Tool
Cover
Special Tool
Raise Up
Special ToolSpecial Tool
Insert Mark
Terminal
Retainer
Terminal Retainer
[Retainer at Full Lock Position]
Stopper
[Retainer at Temporary Lock Position]Terminal
Retainer
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±20
30
Wire Harness Repair Manual (RM1022E)
Type J (For Insulation Displacement Connector)
(1)Separate Connector
Using a special tool, release the lock and separate the
connector into 2.
NOTICE:
Do not apply too muck force to the lock arm.
(2)w/ Cover : Open Connector Cover
Using a special tool, release the lock and open the cover.
NOTICE:
Do not apply too much force to the lock arm.
Type K (0.64 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.
Page 1450 of 2389
Good Bad
Special Tool
Lock Special
Tool
Special Tool
Lock
Special Tool
Lock Housing
Upper
Housing
B±21
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
31
Wire Harness Repair Manual (RM1022E)
Type L (0.64 of Insulation Displacement Connector (IDC)
Type)
(1)Remove the Lower Housing
Using a special tool, release the lock and remove the lower
housing.
NOTICE:
Do not apply too much force to the lock arm.
Mark the upper housing and lower housing to
prevent mistakes when putting them together.
(2)Remove the Upper Housing
Using a special tool, release the lock and remove the upper
housing from the lock housing.
NOTICE:
Do not apply too much force to the lock arm.
Mark the upper housing and lower housing to
prevent mistakes when putting them together.
Type M (0.64 of Splash Proof Connector)
(1)Release Terminal retainer.
Insert Special Tool at the location shown in the figure
left.
Page 1451 of 2389
Terminal Retainer
[Retainer at Lock Position]
[Retainer at Unlock Position]Terminal Retainer
Rear Holder
Rear Holder
[Rear Holder at Lock Position]
[Rear Holder at Unlock Position]Rear Holder
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±22
32
Wire Harness Repair Manual (RM1022E)
Move Special Tool in the direction of arrow.
(2)Release Rear holder.
Insert Special Tool at the location shown in the figure
left.
Move Special Tool in the direction of arrow.
NOTICE:
Do not remove Rear holder from Connector
housing.
If Rear holder completely comes off the housing,
replace Connector with a new one.
Page 1452 of 2389
Rear Holder
Locking Clip
Pull Out
Connector
Wire Harness
Terminal
Retainer
Locking
Clip ºWaterproof Typeº
Special
Tool
B±23
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
33
Wire Harness Repair Manual (RM1022E)
4. Disconnect Terminal from Connector
(a)Determine the primary locking system from the
charts.
1. Lock Located on terminal
2. Lock Located on connector
3. Method of entry and operation
(b)Push the terminal gently into the connector and hold
it in this position.
(c)Insert the special tool into the connector in the
direction shown in the chart.
(d)Move the locking clip to the unlock position and hold
it there.
NOTE: Do not apply excessive force to the terminal.
Do not pry on the terminal with the special tool.
(e)Carefully withdraw the terminal from the connector by
pulling the lead toward the rear of the connector.
NOTE: Do not use too much force. If the terminal
does not come out easily, repeat steps (a) through
(e).
Page 1453 of 2389

Locking Clip Terminal Retainer
4.8 Type ºNon±Waterproof Typeº
SST Tool Hole
Terminal LanceStopper Portion 0.64 Type
Non±waterproof type TLC housing
Insert the tool from wire harness side
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±24
34
Wire Harness Repair Manual (RM1022E)
(f)Insert the SST into the connector in the direction
shown in the chart.
(g)Insert the SST fully to the tool hole, and push the
terminal lance.
NOTICE:
The terminal has a lance shape, therefore, the
housing may be damaged and the terminal may get
stuck if forcibly pried by wires etc.
Insert the SST so that the stopper portion surface is
facing up.
(h)Carefully withdraw the terminal from the connector by
pulling the lead toward the rear of the connector.
NOTICE:
Removal of the terminal from housing cavity will cause
damage to the wire seal section, deteriorating
waterproofing performance. Replace the connector
with a new one.
NOTICE:
Do not insert the special tool into the female terminal
box. If you do so, replace the terminal with the new one
whether the terminal is broken or not.
NOTICE:
As for Non±waterproof type TLC housing, insert the
special tool into the housing from wire harness side.
Page 1454 of 2389
Tool Hole
Terminal LanceSpecial
Tool
Special
Tool
Tool HoleSpecial Tool
Terminal
Lance Special Tool 0.64 Type
B±25
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
35
Wire Harness Repair Manual (RM1022E)
Insulation Displacement Connector Type
(a)Using a special tool, push the terminal lance from the
tool hole.
(b)Carefully withdraw the terminal from the connector by
pulling the lead toward the rear of the connector.
NOTICE:
Do not use too much force. If the terminal does not
come out easily, repeat step (a).
Always change the wire with the repair wire, in
accordance with page B±27.
Page 1455 of 2389
Terminal Deformation
(1) Terminal Bending in Vertical Direction
(2) Terminal Bending in Horizontal Direction1° or less
1° or less
3° or less
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±26
36
Wire Harness Repair Manual (RM1022E)
5. Inspect the terminal and the connector for
damage.
NOTE:
The locking clip is easily damaged.
Do not reuse the damaged part.
Page 1456 of 2389

Step 3. Replace the terminal.
Cut Existing
terminal
New Terminal with lead
82998±12200
Stripped insulation length (A)
approximately 8 to 11 mm
Existing
HarnessSupplied lead
with New Terminal AA
B±27
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
37
Wire Harness Repair Manual (RM1022E)
1. Cut the Old Terminal from the Harness.
(a)Use the new wire lead as a guide for proper length.
NOTE: If the length of wire removed is not
approximately the same length as the new piece, the
following problems may develop:
Too short ±± tension on the terminal, splice, or
the connector, causing and open circuit.
Too long ±± excessive wire near the connector,
may get pinched or abraded, causing a short
circuit.
HINT: When connecting a wire harness at there or more
spots to the same connector, cut the wire harness as
shown on the left.
2. Select the correct replacement terminal with
lead, from the supply parts.
3. Strip insulation from wire on the harness and
replacement terminal lead.
Start stripping at least 8 mm (0.31 in.) to 11 mm (0.43 in.)
away from the end of the existing harness at vehicle side
and also from the end of the repair wire.