Lexus ES300 (2002 year). Service manual - part 229

Example:

Back of the 
Connector Body

P/N 90980–10854

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TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Manual (RM1022E)

NOTICE:

When the terminal used is gold plated, be sure to
replace it with a gold plated terminal when marking
repairs.

Do not use male and female terminals which are
made of different materials from each other.

2.

Connector Body

(a)

Identify the part number of the corresponding
terminal with wire according to the above–mentioned
1.

(b)

Identify the part number of the connector body by
picking out the correct one from the illustrations
according to the number of terminals and the shape.

HINT:

(a)

If you can find no connector which matches the type
you require, pick out male and female connector
bodies as a set which have more terminals than you
require.

For the combined terminal type connector body, pick
out and appropriate connector body for each terminal
being used.

Example:
When two types of terminal are used in one connector
body, pick out a male and female for two different
connector bodies.

(b)

The part number has been stamped on the back of
the connector body. (This will continue to be done to
new types of connector.)

B

Hole Plug

Connector Body

Terminal 
Packing

Small (Red)

Large (Yellow)

Medium (Blue)

Medium (Blue)

1.0–2.0 mm

Large (Yellow)

3.0–5.0 mm

Wire Outside

Diameter

Sleeve Size

(Color)

Small (Red)

0.2–1.0 mm

Wire Outside Diameter

Insulation

Calipers

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Manual (RM1022E)

3.

Hole Plug/Terminal Packing

(a)

Identify the part number of the appropriate terminal
with wire/connector body from the illustrations of
waterproof type connector according to the
above–mentioned  1 and 2.

(b)

Identify the part number of the hole plug/terminal
packing from the corresponding illustration.

4.

Sleeve

When connecting two wires using a sleeve, select the
sleeve according to the following table.

(a)

When size is based on the outside diameter of the
wire.

B

0.3

0.5

0.85

1.25

2

3

5

S

M

M

M

M

L

L

0.3

M

M

M

M

M

L

L

0.5

M

M

M

M

L

L

L

0.85

M

M

M

M

L

L

L

1.25

M

M

L

L

L

L

––

2

L

L

L

L

L

L

––

3

L

L

L

L

––

––

––

5

∗

 Nominal size of the wire

∗ ∗

Twist Evenly

Calipers

Nominal Size of Wire

Wire Lead
Diameter

Wire Outside Diameter

Nominal Size

Insulation

Stripped Wire Harness Section

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TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Manual (RM1022E)

(b)

When size is based on the nominal size of the wire.

Sleeve size
S : Small (Red)
M : Medium (Blue)
L : Large (Yellow)

HINT:

To calculate the ”Nominal Size” of the wire.

Nominal size =

3.14 x (Diameter of stripped wire harness)

2

4

HINT:

Outside Diameter and Nominal Size

B

Example:

Press Down

Press Down

Pull Up

Pull Up

Refereance:

(mm)

Example:

Up

Tool

Terminal Retainer

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Manual (RM1022E)

Step 2.

Disconnect the Terminal from the Connector.

1.

Disconnect Connector

To pull apart the connectors, pull on the connector itself,
not the wire harness.

HINT:

Check to see what kind of connector you are

disconnecting before pulling apart.
Press down type is mainly used.

2.

Prepare the Special Tool

HINT:

To remove the terminal from the connector, please

construct and use the special tool or like object shown on
the left.

3.

Disengage the double locking device or terminal
retainer.

(a)

Locking device must be disengaged before the
terminal locking clip can be released and the terminal
removed from the connector.

(b)

Use a special tool or the terminal pick to unlock the
double locking device.

NOTICE:
Do not remove the terminal retainer from connector
body.

B