Page 1457 of 2389

Good Example:
Bad Example:
(Wire insulation is Stripped at a Slant)
(Wire Lead is Cut)
(Insulation Remains on the Lead)
Wire Harness Outside Diameter
Insulation Calipers
Nominal Size of the Wire
Twist EvenlyCalipersWire Lead
Diameter
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±28
38
Wire Harness Repair Manual (RM1022E)
NOTICE:
Take care not to damage the wire when stripping the
wire harness lead. After finishing the operation,
visually inspect the wire. If there is any damage,
perform the operation again.
HINT:
If the wire size is not known, start with largest stripper hole
and work down until a clean strip of the insulation is
removed without nicking or cutting the wire lead.
4. Select Correct Size of Sleeve from the Supply
Parts.
(a)Measure the diameter of wire by using the measuring
device as following:
When size is based on the outside diameter of the
wire harness
Measure the outside diameter of the wire harness by
placing a measuring device, such as a micrometer or
Vernier Caliper, across the diameter of the insulation on
the lead and taking a reading.
When size is based on the nominal size of the wire
lead.
Measure the diameter of the wire lead by placing a
measuring device, such as a micrometer or Vernier
Caliper, across the diameter of the wire lead and taking
a reading.
HINT:
To calculate the ºnominal sizeº of wire
Nominal size=3.14 x (Diameter of wire lead)
2
4
Page 1458 of 2389
Small (Red)
Medium (Blue)
Large (Yellow)
Good Example
Two Stripped Wires Sleeve (Blue)
Bad ExamplePressure±Contact
Section
Wire in
Short PositionWire Bend
Special Tool
B±29
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
39
Wire Harness Repair Manual (RM1022E)
(b)Use the table to determine proper sleeve size
Part NumberNominal size of wire
(Outside Diameter of
wire)
Small 82999±12010 0.3 or less
(1.0 ± 0.2 mm)
Medium 82999±12020 0.5 ± 1.25
(2.0 ± 1.0 mm)
Large 82999±12030 2 or more
(5.0 ± 3.0 mm)
NOTE: For details, refer to sleeve size table on item
4 of STEP 1
5. Crimp the Replacement Terminal Lead to the
Harness Lead.
(a)Overlap the two stripped wire ends inside the sleeve
as illustrated on the left.
HINT: You might find it easier if you use a miniature
special tool as a guide as you insert wires into the sleeve.
Page 1459 of 2389

Sleeve Color MarksCrimping
Tool
ºCLOSE HEREº
Contact
ºINSº Position
10 mm (0.39 in.)
Three or More Times
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±30
40
Wire Harness Repair Manual (RM1022E)
(b)The crimping tool (AMP Part No. 169060) has color
marks on it. Place the sleeve in the correct section of
the tool according to the color of the sleeve itself.
HINT: For the crimping tool, AMP ºPart No. 169060º is
convenient to use.
(c)With the center of the sleeve correctly placed
between the crimping jaws, squeeze the crimping tool
until either end comes into contact at the section
marked by ºCLOSE HEREº.
HINT: Check to see that the sleeve and wires are still in
the correct position before closing the crimping tool ends
with steady pressure.
(d)Pull the joined wires to either end. Make sure that they
are joined firmly by the sleeve.
NOTICE:
If the joined wires come loose the splice is defective,
so replace the sleeve and repeat the procedure.
(e)Crimp both ends of the sleeve with the crimping tool
at the ºINSº position.
6. Protect Joined Section
Wrap silicon tape around the joins to protect them from
moisture.
NOTE: This job is required in repairs of the engine
compartment, under the floor and other moisture entry
positions.
Page 1460 of 2389

Three or More Times
10 mm (0.39 in.)
Tape overlapping
10 mm (0.39 in.)
Two or More Times
Finish
B±31
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
41
Wire Harness Repair Manual (RM1022E)
HINT:
Before starting the operation, thoroughly wipe dirt and
grease off the sections to be joined.
If the adhesive surfaces of two tapes come in contact
they will stick together and will not come apart, so do
not remove the backing film except when using the
tape.
Do not let oil and dust, etc. get on the tape surface.
(a)Ready about 100 mm (3.94 in.) of silicon tape (Part
No. 08231±00045) and peel off the film.
(b)Stretch the silicon tape until its width is reduced by
half.
(c)About 10 mm (0.39 in.) from the end of the sleeve,
wrap the silicon tape around the sleeve three or more
times while stretching the tape.
(d)Wrap the remaining part of the sleeve with half of the
tape overlapping at each turn.
(e)Firmly wrap the tape two times or more about 10 mm
(0.39 in.) from the other end of the sleeve, then wrap
the tape back towards the start again and firmly finish
winding the tape around the center of the sleeve.
Page 1461 of 2389

Special ToolLocking clip
Special Tool Terminal Lance ºInsulation Displacement Connectorº
Terminal Lance º0.64 Typeº
Special Tool
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±32
42
Wire Harness Repair Manual (RM1022E)
Step 4. Install the terminal into the connector.
HINT:
(a)Make sure the terminal is positioned correctly.
(b)Insert the terminal until the locking clip locks firmly.
(c)Insert the terminal with terminal retainer in the
temporary lock position, if equipped.
NOTE: If reusing a terminal, check that the locking clip is
still in good condition and in the proper position.
(a)If it is on the terminal and not in the proper position,
use the special tool to gently bend the locking clip
back to the original shape.
(b)Check that the other parts of the terminal are in their
original shape.
NOTICE:
Do not readjust or reuse the terminal lance of the
insulation displacement connector type terminal.
Always change the wire with the repair wire.
NOTICE:
As for 0.64 type terminal, do not adjust the terminal
lance with the special tool.
Splash Proof Type Connector
NOTICE:
Removal of the terminal from housing cavity will
cause damage to rubber plug material (the wire
seal), deteriorating waterproofing performance. Be
sure to replace the housing with a new one.
Check the withdrawn terminal for the following if
trying to use it again.
It is free of deformation and damage
It is free of adherents such as rubber plug
material (wire seal)
Replace any deformed terminal.
Page 1462 of 2389
Wire
ºClickº
ºClickº º0.64 IDC Typeº
ºClickº ºInsulation
Displacement
Connectorº
Good Example:
Bad Example:
B±33
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
43
Wire Harness Repair Manual (RM1022E)
1. Push the Terminal into the Connector until you
hear a ºclickº.
NOTE: Not all terminals will give and audible ºclickº.
NOTICE:
After repairing, never let only one harness stretch.
In cese that it becomes short, do over again using
the repair wire.
Page 1463 of 2389
![TOYOTA CAMRY V20 1986 Service Information Terminal Retainer
Example:
Good
Bad Good
Bad
[Female]
[Male] *Terminal
In Short
Position
*Terminal
In Short
Position Double Locking
Device
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±34 TOYOTA CAMRY V20 1986 Service Information Terminal Retainer
Example:
Good
Bad Good
Bad
[Female]
[Male] *Terminal
In Short
Position
*Terminal
In Short
Position Double Locking
Device
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±34](/manual-img/14/57449/w960_57449-1462.png)
Terminal Retainer
Example:
Good
Bad Good
Bad
[Female]
[Male] *Terminal
In Short
Position
*Terminal
In Short
Position Double Locking
Device
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
B±34
44
Wire Harness Repair Manual (RM1022E)
2. Double Locking Type Connector
(with terminal retainer or double locking device)
The connector is fitted with a terminal retainer, or a double
locking device, it is in the temporary lock position at insert
the terminal.
Type A (For 1.0, 1.0II, 1.3, 1.8, 2.3II 4.8 and 8.0 of
Non±Waterproof Type Connector)
(a)Insert the terminal.
HINT:
1. Make sure the terminal is positioned correctly.
2. Insert the terminal with terminal retainer in the
temporary lock position.
(b)Insert the terminal until the locking clip locks firmly.
HINT:
1. Pull the terminal back gently to check whether it is
locked correctly.
2. If it cannot be inserted easily, check the terminal and
the connector for damage.
NOTE: If the terminal to locking clip does not lock firmly,
the double locking device cannot lock or terminal retainer
does not lock at full lock position so the terminal backs out
from connector.
(c)Close terminal retainer or double locking device.
The connector is fitted with a terminal retainer, or a
double locking device, return it to the full lock position.
Page 1464 of 2389
Full Lock Position
[Female]
Full Lock Position
[Female]
Full Lock Position
[Male]
Terminal Retainer
at Temporary
Lock Position
Terminal Locking
Clip
B±35
TERMINAL AND CONNECTOR REPAIR±TERMINAL REPLACEMENT
45
Wire Harness Repair Manual (RM1022E)
Type B (For 1.8, 2.3, 2.3II, 4.8, 6.3 and 8.0 of Waterproof
Type)
(For Male Connector)
(a)Insert the terminal.
HINT:
1. Make sure the terminal is positioned correctly.
2. Insert the terminal with terminal retainer in the
temporary lock position.
(b)Insert the terminal until the locking clip locks firmly.
HINT:
1. Pull the terminal back gently to check whether it is
locked correctly.
2. If it cannot be inserted easily, check the terminal and
the connector for damage.