Need a tutorial on replacing a terminal in a connector

[hotspur]

3VZ-FE engine, Camry LE V6, 1992.

A 'mechanic' broke a terminal inside a plug, by pulling on the harness near to where the harness connects to the solenoid that is located on top of the hydraulic pump (for the power steering and the cooling fan motor).

The damaged plug is for the connector labeled S1 in the electrical wiring diagrams.


A section in the electrical wiring diagram does address the issue of replacing terminals in connectors. However, that clarity of that section rivals the clarity of instructions sometimes found in 'cheap' DIY-assembly goods.

For example:


Is there a video tutorial, or would someone write a fuller description I have a chance of following, please?

Also, I'm assuming the Toyota dealer sells replacement terminals for connector repairs! .......?

[71Corolla]

Is it possible to splice in a replacement connector? I have a tool I made out of a jewelers screwdriver, but sometimes it is very difficult to get the pins out depending on the room I have to work with. Soldering, heat shrink tubing, and some electrical tape usually does the job.

I don't know if the dealer sells kits for repairing connectors or not, I have my doubts. Someone with more knowledge can chime in.

[hotspur]

I'm hoping to avoid the time and effort of searching junk yards for a used connector.

Can you tell from the diagram of the S1 connector how to unlock the retainer in that plug?

I'll have to check tomorrow whether the dealer sells parts for repairing connectors. You would think they would, as the Toyota wiring diagram suggests repairing connectors.

The dealer already told me it does not sell replacement plugs - but only the entire harness for several hundred $.

[Buurin]

Originally Posted by hotspur

I'm hoping to avoid the time and effort of searching junk yards for a used connector.

Can you tell from the diagram of the S1 connector how to unlock the retainer in that plug?

I'll have to check tomorrow whether the dealer sells parts for repairing connectors. You would think they would, as the Toyota wiring diagram suggests repairing connectors.

The dealer already told me it does not sell replacement plugs - but only the entire harness for several hundred $.

Can you look for a 5-digit number on the plug and post it here? I have a copy of the harness repair manual and will try to look up that plug for you and confirm how to "take it apart". But the manual pretty much says it all. Look for a slot marked with a triangle OR teardrop. That is where you stick a jeweler screwdriver to lift up the lock and free it. I just use a 1.0-1.2mm flat jeweler screwdriver as is for these work.

Is it the plug shell or a terminal within that broke?

You just need to give the dealer the right part number (which can be derived from the 5-digit number I ask for above). I have ordered connector shells from them before. Some can be ordered, some cannot, and they won't be cheap. Yes, even the individual terminals (they call them "repair splice") but again they aren't cheap. Heck if I can find your plug in my box of wiring I'll sell it and the wires to you and it'd still be cheaper than the dealer.

[hotspur]

Thank you. I'll look for the part number on the connector, and get back to you - but that will probably take a few days because I don't have ramps to raise the car up on, and I'll have to ask to use the ramps of an acquaintance.

It's one of the terminals inside the shell that's broken. (By th way, the car badly overheats extremely easily in slow traffic as a result, especially when running A/C.]

[abew330]

soo the actual connector broken inside? if so i would think you will need a replacement connector. try ebay and look for items within a certain distance from your location (to ensure speedy delivery)

i have broken few coil and injector plug connectors even being very careful while removing the plug

if your car is overheating as a result i don't think it is wise to run the A/C

if the plug isnt broken inside i would get a hold of a couple flat head precision screwdrivers to take apart the plug

[hotspur]

Well, what's broken is one of the two metal terminals inside the shell of that particular plug.

My understanding is that after unlocking a retaining mechanism, such metal terminals can be removed and replaced, and then the retaining mechanism can be re-locked.