Toyota Wiring (1991-2005 year). Manual — part 2

Fuse Case

Test Bulb

Short [A]

SW1

Short [B]

Relay

Light

Short [C]

SW2

Solenoid

Disconnect

Disconnect

Disconnect

To Ignition SW
IG Terminal

INTRODUCTION–HOW TO PERFORM FOR SYSTEM INSPECTION

A–7

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Wire Harness Repair Manual (RM1022E)

4.

Finding a Short Circuit

(a)

Remove the blown fuse and eliminate all loads from
the fuse.

(b)

Connect a test bulb in place of the fuse.

(c)

Establish conditions in which the test bulb comes on.

Example:
[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 while
watching the test bulb. The short lies between the
connector where the test bulb stays lit and the
connector where the bulb goes out.

(e)

Find the exact location of the short by lightly shaking
the problem wire along the body.

CAUTION:

(a)

Do not open the cover or the case of the ECU
unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by static
electricity.)

(b)

When replacing the internal mechanism (ECU
part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the
terminals of leads from the IC, etc. of the
replacement part (spare part).

A

Push

Equal Amperage Rating

A–8

INTRODUCTION–CIRCUIT PROTECTION

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Wire Harness Repair Manual (RM1022E)

CIRCUIT PROTECTION

All electrical circuits are protected against excessive loads which might occur because of shorts or
overloads in the wiring system. Such protection is provided by a fuse, circuit breaker, or fusible link, A
short circuit may cause a fuse to blow or a circuit breaker to open.

RESET CIRCUIT BREAKER

1.

Remove Circuit Breaker

(a)

Disconnect the negative (–) cable from the battery.

(b)

Remove the circuit breaker.

2.

Reset Circuit Breaker

(a)

Insert the needle into the reset hole and push it.

(b)

Using an ohmmeter, check that there is continuity
between both terminals of the circuit breaker.

If continuity is not as specified, replace the circuit breaker.

HINT:

If replacing the circuit breaker, be sure to replace

it with a breaker with an equal amperage rating.

3.

Install Circuit Breaker

(a)

Install the circuit breaker.

(b)

Connect the negative (–) cable to the battery.

HINT:

If a circuit breaker continues to cut out, a short

circuit is indicated. Have the system checked by a qualified
technician.

A

Equal Amperage Rating

Equal Amperage Rating

Puller

INTRODUCTION–CIRCUIT PROTECTION

A–9

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Wire Harness Repair Manual (RM1022E)

REPLACEMENT OF FUSE AND FUSIBLE LINK

HINT:

If replacing the fuse or fusible link, be sure to

replace it with a fuse or fusible link with an equal amperage
rating.

NOTICE:

1.

Turn off all electrical components and the ignition
switch before replacing a fuse or fusible link. Do
not exceed the fuse or fusible link amperage rating.

2.

Always use a fuse puller for removing and
inserting a fuse. Remove and insert straight in and
out without twisting. Twisting could force open the
terminals too much, resulting in a bad connection.

If a fuse or fusible link continues to blow, a short circuit is
indicated. The system must be checked by a qualified
technician.

HINT:

The puller is located at Junction Block No.2.

A

Reference:

(mm)

B–1

TERMINAL AND CONNECTOR REPAIR–PREPARATORY ITEMS

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Wire Harness Repair Manual (RM1022E)

PREPARATORY ITEMS

Crimping tool

AMP Part No. 169060

For caulking
press sleeves

Tool

Special tool

Refer to the following illustration

To remove the
terminal

SST

09991–00500

To remove the
0.64 connector
terminal

Gauge

Caliper

0–150 mm

To measure the
diameter of the
core

Others

82999–12010 (Red)

Press sleeve

82999–12020 (Blue)
82999–12030 (Yellow)

To connect wires

Others

Silicon tape

08231–00045

To waterproof
the connected
section

Special Tool

HINT:

To remove the terminal from the connector, please

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

Preparation of the SST to release the 0

.64

connector terminal.

SST 09991–00500

HINT:
This is a SST for releasing terminals from 0.64 connectors.

B

TERMINAL AND CONNECTOR REPAIR–CONNECTOR REPAIR

B–2

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Wire Harness Repair Manual (RM1022E)

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.

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.

B

B–3

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Manual (RM1022E)

TERMINAL REPLACEMENT

These steps must be followed when replacing a terminal.

Step 1. Identify the connector and the terminal type.

Step 2. Disconnect the terminal from the connector.

Step 3. Replace the terminal.

Step 4. Install the terminal into the connector.

B

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–4

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Wire Harness Repair Manual (RM1022E)

Step 1.

Identify the connector and the terminal type.

Confirm whether the connector you require is the non–waterproof, waterproof or combined terminal type
connector from the pictures provided in the following charts.

Connector

Description

Non–Waterproof Type

Those connectors which are not of the
waterproof or combined terminal type.

Waterproof Type

Waterproof material (hole plug or terminal
packing) is provided on the terminal/connector
body.

Combined Terminal Type

Terminals of different shape/size are located in
one connector.

1.

Terminal with Wire

Identify the part number of the terminal with wire by picking
out the corresponding illustration from the pictures
provided on the following charts.

HINT:

In some of the illustrations, there are two part

numbers for the same illustration of terminal with wire,
because although the shapes of the terminals are
completely the same, there is a difference in with /without
gold–plating (gilded).

Remark:

The length of the wire connected to the

terminal is approximately 150 mm.

B

Example:

Back of the
Connector Body

P/N 90980–10854

B–5

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