Toyota RM06H0E engine. Manual — part 2
Equal Amperage Rating
Equal Amperage Rating
Puller
A–9
INTRODUCTION–CIRCUIT PROTECTION
13
Wire Harness Repair Manual
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
memo
14
Wire Harness Repair Manual
A
15
Wire Harness Repair Manual
TERMINAL AND CONNECTOR REPAIR
PREPARATORY ITEMS
B–1
. . . . . . . . . . . . . . . . . . . .
CONNECTOR REPAIR
B–2
. . . . . . . . . . . . . . . . . . . . .
TERMINAL REPLACEMENT
B–3
. . . . . . . . . . . . . . . .
HOW TO INSTALL AND REMOVE
SPECIAL CONNECTORS
B–47
. . . . . . . . . . . . . . . . .
B
16
Wire Harness Repair Manual
B
Reference:
(mm)
B–1
TERMINAL AND CONNECTOR REPAIR–PREPARATORY ITEMS
17
Wire Harness Repair Manual
PREPARATORY ITEMS
Tool
Crimping tool
AMP Part No. 169060
For caulking press
sleeves
Tool
Special tool
Refer to the following illustration
To remove the
terminal
Tool
SST
09991–00500
To remove the 0.64
connector terminal
SST
09992–01030
To remove the 0.64 II
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
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.
Preparation of the SST to release the 0
.64 II
connector
terminal.
SST 0999
2
-0
1030
HINT:
This is a SST for releasing terminals from 0.64 II
connectors.
B
TERMINAL AND CONNECTOR REPAIR–CONNECTOR REPAIR
B–2
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Wire Harness Repair Manual
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
19
Wire Harness Repair Manual
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
Type
Male
Male
Male
Female
Female
Female
F-7
040III IDC
040III
Repair Wire (Non-Waterproof Type)
TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE
040IV
Type
Type
P/N
P/N
P/N
82998-12670
82998-12680*
82998-12690
82998-12700*
82998-12660
82998-12640
82998-12740
Sleeve : Medium (Blue)
Sleeve : Medium (Blue)
Sleeve : Medium (Blue)
Sleeve : Medium (Blue)
Sleeve : Medium (Blue)
A = 1.0mm
D = 2.0mm
E = 0.5
A
D
A = 1.8mm
D = 2.0mm
E = 0.5
D
A
A = 1.0mm
D = 2.0mm
E = 0.5
A
D
A = 1.8mm
D = 2.0mm
E = 0.5
D
A
A = 1.8mm
D = 2.1mm
E = 1.25
A
D
82998-12690
82998-12700*
TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT
B–4
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Wire Harness Repair Manual
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
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