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.

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.

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

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.

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.)

3. Hole Plug/Terminal Packing

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.

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.

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

Wire Outside Diameter	Sleeve Size (Color)
0.2-1.0 mm	Small(Red)
1.0-2.0 mm	Medium(Blue)
3.0-5.0 mm	Large(Yellow)

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

Sleeve size

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

*	0.13	0.22	0.3	0.5	0.85	1.25	2	3	5
0.13	-	-	-	S	-	-	-	-	-
0.22	-	-	-	S	-	-	-	-	-
0.3	-	-	S	M	M	M	M	L	L
0.5	S	S	M	M	M	M	M	L	L
0.85	-	-	M	M	M	M	L	L	L
1.25	-	-	M	M	M	M	L	L	L
2	-	-	M	M	L	L	L	L	-
3	-	-	L	L	L	L	L	L	-
5	-	-	L	L	L	L	-	-	-

*Nominal size of the wire

HINT:

To calculate the "Nominal Size" of the wire.

Nominal size =

3.14 x (Diameter of stripped wire harness)²

HINT:

Outside Diameter and Nominal Size