Toyota wire harness repair manual pdf

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Product added! Browse Wishlist. The product is already in the wishlist! Description Additional information Description Toyota wire harness repair manual pdf contains help for troubleshooting and will support you how to fix your problems immediately.

A After any electrical repair is made, always test the circuit by operating the devices in the circuit. This confirms not only that the repair is correct, but also that the cause of the complaint was correctly identified. Terminal type number name The terminal type number naming system has changed the metric system will be used in place of the inch system. New terminal type No. The insulators are color—coded in order to distinguish each wire.

The base colors or the stripe patterns is used to make difference between insulators. Each color of wires is indicated by the abbreviation in the repair manual and the electrical wiring diagram. There are the male terminal and the female terminal.

The types of terminals are decided by tab width of male terminal. And the terminal with the rubber plug or the rubber ring is used in the part, such as the engine compartment, which become wet.

For the circuit with slight current at EFI system or ABS system, the gold—plated terminal is introduced for ensuring reliabilities. As the number of the circuit is increasing recently, there are new types of parts introduced. For example, there is the hybrid type housing, which is a combination of terminals with different tab width, such as the power source terminal or the signal terminal. Also, new type of connector such as the double lock housing, which is designed with the retainer in addition to the lance to prevent terminal from slipping off, is available.

The new type of connectors are produced to realize higher product reliabilities and utilized widely recently. The major characteristics of these new connectors are shown in the table 1. There are two types of lances: housing lance, which is inside the housing and terminal lance, which is inside the terminal.

Extension of Housing Housing This is to prevent deformation of the terminal when it is inserted diagonally. Extension Terminal Shortening 3. Change of Locking Shape Expansion of contact section Stabilization of contact pressure This improves the close fit of locking and you can hear the click sound and feel that the connector is completely installed.

Therefore, inspect the trouble with due regard for safety. Establish conditions in which voltage is present at the check point. This check can be done with a test bulb instead of a voltmeter. Relay [C] SW2 Solenoid 2. Continuity and Resistance Check a Ohmmeter b Disconnect the battery terminal or wire so there is no voltage between the check points.

Contact the two leads of an ohmmeter to each of the check points. When touching the two leads in reverse, there should be no continuity. There should be continuity between the respective terminals of the bulb together with a certain amount of resistance. Apply the two leads of the ohmmeter to each of the terminals. Apply battery voltage and check that the bulb light up. Finding a Short Circuit Remove the blown fuse and eliminate all loads from the fuse.

The short lies between the connector where the test bulb stays lit and the connector where the bulb goes out. Find the exact location of the short by lightly shaking the problem wire along the body. If the IC terminals are touched, the IC may be destroyed by static electricity. 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.

Remove Circuit Breaker Push a b 2. A Disconnect the negative — cable from the battery. Remove the circuit breaker. Reset Circuit Breaker a Insert the needle into the reset hole and push it. 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. Equal Amperage Rating 3. Install Circuit Breaker Install the circuit breaker.

HINT: If a circuit breaker continues to cut out, a short circuit is indicated. Have the system checked by a qualified technician. 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. 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. 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.

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. Replace both the male and female connector parts with the eight terminal part, transferring the terminals from the old connectors to the new connectors. 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.

Replace the original connector with two new connectors, one connector for one type of terminal, another connector for the other type of terminal. 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. Replace all existing terminals with the new terminals, then insert the terminals into the new connector. 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. Step 1. Identify the connector and the terminal type. B Step 2. Disconnect the terminal from the connector. Step 3. Replace the terminal. Step 4. Install the terminal into the connector. 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. 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. Remark: The length of the wire connected to the terminal is approximately mm. Connector Body a b Identify the part number of the corresponding terminal with wire according to the above—mentioned 1.

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.