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REPAIR CONNECTOR REPLACEMENT/WIRING HARNESS CONNECTION

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Repair Connector Replacement

Vehicle-side Connector Cutting

1. If tubing or electrical tape is used to protect the connector wiring harness, cut into it being careful not cut or damage the wiring, and expose approx. 200 mm {7.84 in} of the wiring from the connector.

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2. Cut the wiring harness once at the position near the connector so as to leave a long length of wiring harness on the vehicle side, align the length with the repair-use connector wiring harness, and then recut at the wiring harness on the vehicle side or the repair-use connector wiring harness at the appropriate position.

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Caution

• When repairing a CAN-related wiring harness, cut the wiring harness in a range within 80 mm {3.1 in} from the connector area shown in the figure.

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Caution

• Cut longer in consideration of the amount of wiring harness length which will be soldered.

• If the cut wiring harness length is different than the repair-use wiring harness length, the following problems may occur.

― If too short: Tension will be applied to the terminal, wiring harness connection area, or the connector resulting in an open circuit.

― If too long: A short may occur due to pinching and wear of the extra length of wiring harness near the connector.

Note

• If several wiring harnesses are connected to the same connector, stagger the cut positions so that the repair positions do not overlap as shown in the figure to prevent thickening of the wiring harness after repair.

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Wiring Harness Connection

Special Service Tool (SST)

49 JP03 001

CRIMPING TOOL

Connection Procedure Using Soldering

Caution

• Perform “Connection Procedure Using Crimp Terminal” for aluminum wiring connection.

1. Line up the cores of the wiring harnesses to be connected as shown in the figure.

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2. Twist together both of the cores.

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3. Apply solder to the twisted core area.

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Caution

• Soldering for a long period of time could affect the surrounding electrical circuit. Apply soldering for an extremely short period of time.

4. Set the heat-shrinkable tubing to the soldered area and shrink the heat-shrinkable tubing at a temperature of approx. 100 °C {212 °F} using a drier until the plastic melts on both ends.

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Caution

• Completely shrink the heat-shrinkable tubing to the wiring harness leaving no gaps.

• Perform the work being careful not to melt the insulation of the wiring harness due to excessive heat.

Connection Procedure Using Crimp Terminal

Caution

• Always use the special service tool (49JP 03 001) when performing this procedure. If a similar tool other than the special service tool is used, the possibility of a poor connection occurring due to insufficient crimping is high even though it may appear that the crimping was done successfully.

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1. Select the appropriate crimp terminal and the crimping area of the special service tool according to the thickness of the wiring harness to be repaired.

Size (mark)

Outer diameter

Compatible wiring size

Crimping area of special service tool

S

3 mm {0.1 in}

0.5—1.0 sq

1.25

M

4 mm {0.2 in}

1.25—2.5 sq

2

Size (mark)	Outer diameter	Compatible wiring size	Crimping area of special service tool
S	3 mm {0.1 in}	0.5—1.0 sq	1.25
M	4 mm {0.2 in}	1.25—2.5 sq	2

2. Squeeze the grips tightly until the ratchet of the special service tool detaches and open the handle of the special service tool.

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3. Place the appropriate crimp terminal on the crimping area of the special service tool and secure the crimp terminal by lightly squeezing the grips to a level that the crimping terminal does not deform.

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Caution

• Set the cutter blade of the special service tool inside the scribed line (cutter blade position indicator line of special service tool) on the crimp terminal.

4. Insert the wiring harness to be connected into the crimp terminal until it reaches the contact point inside the terminal.

Caution

• Verify that all the cores have been inserted without buckling.

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5. Crimp the crimp terminal completely by squeezing the grips of the special service tool tightly until the ratchet detaches.

6. Pull on the connected wiring harness to verify that the wiring harness does not pull out of the crimp terminal.

7. Perform the same procedure from Steps 3 to 6 for the opposite side.

8. Set the heat-shrinkable tubing to the connection area so that it is centered and shrink the heat-shrinkable tubing at a temperature of approx. 100 °C {212 °F} using a drier until the plastic melts on both ends.

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Caution

• Completely shrink the heat-shrinkable tubing to the wiring harness leaving no gaps.

• Perform the work being careful not to melt the insulation of the wiring harness due to excessive heat.

Taping work

1. Tape the surface of the heat-shrinkable tubing.

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Caution

• Remove moisture, oil, and dust from the area to be taped before doing the taping.

• Firmly tape the ends so that they do not peel off.

• Always overlap the tape when wrapping.

• Wrap the tape until it completely covers the heat-shrinkable tubing.