Connector Repair - Toyota Automobile Electrical Repair And Modification

B–2

CONNECTOR REPAIR

The repair parts now in supply are limited to those connectors having common shapes and terminal
cavity numbers. Therefore, when there is no available replacement connector of the same shape or
terminal cavity number, please use one of the alternative methods described below. Make sure that the
terminals are placed in the original order in the connector cavities, if possible, to aid in future diagnosis.
1. When a connector with a different number of terminals than the original part is used, select a connector
having more terminal cavities than required, and replace both the male and female connector parts.
EXAMPLE: You need a connector with six terminals, but the only replacement available is a connector
with eight terminal cavities. Replace both the male and female connector parts with the eight terminal part,
transferring the terminals from the old connectors to the new connectors.
2. When several different type terminals are used in one connector, select an appropriate male and female
connector part for each terminal type used, and replace both male and female connector parts.
B
EXAMPLE: You need to replace a connector that has two different types of terminals in one connector.
Replace the original connector with two new connectors, one connector for one type of terminal, another
connector for the other type of terminal.
3. When a different shape of connector is used, first select from available parts a connector with the
appropriate number of terminal cavities, and one that uses terminals of the same size as, or larger than,
the terminal size in the vehicle. The wire lead on the replacement terminal must also be the same size as,
or larger than, the nominal size of the wire in the vehicle. ("Nominal" size may be found by looking at the
illustrations in the section F or by direct measurement across the diameter of the insulation). Replace all
existing terminals with the new terminals, then insert the terminals into the new connector.
EXAMPLE: You need to replace a connector that is round and has six terminal cavities. The only round
replacement connector has three terminal cavities. You would select a replacement connector that has
six or more terminal cavities and is not round, then select terminals that will fit the new connector. Replace
the existing terminals, then insert them into the new connector and join the connector together.
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TERMINAL AND CONNECTOR REPAIR–CONNECTOR REPAIR
Wire Harness Repair Manual (RM1022E)