Connector Availability/Compatibility

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Date: Thu, 1 May 1997 09:23:53 -0400
From: Ed.Wong@astramerck.com
Subject: O2 sensor's snap-click connector
To: "        -         (052)Toy4x4 (a) tlca.org" 

Oh the price of improved build quality....

Toyota has developed over the years a production method (the Toyoda method)
utilizing lots of American business gurus (Demming, Ford, Taylor) and
a few of their own twists (Tachi Ohno).

One of these concepts is Poka-Yoke; the concept of mistake proofing the
assembly line. These are visual aids that help prevent improper
assembly and make it obvious that a part was NOT put together properly.

You may have noticed (and even more so if you look at a late model's
*colour* wiring diagram manual - worth every $, IMHO) that there
are ALOT of connector types - and that many connectors that
are similar in shape are different in colour.

The shape/colour thing was done on purpose - first you may notice
that the wrong connectors will not mate. Those that are close
and that could be *forced* to mate are different colors - so that if
they were put together - it would be obvious.

What does this mean? - you are NOT going to find anything remotely
close in a electronics parts store - believe me - I've looked.

For interior connectors - Molex makes a good range of generic
multi-pin connectors. They are'nt cheap, but if you buy $100 or
so worth of pins and "shells" at least the stuff is on the shelf
when your friends drop over to have you *help* installing
their new CD player. (hmm this sound familiar?).
These connectors make future disassembly MUCH easier - esp
since sub assembleies can be removed to get at other parts
such as the heater core etc..

For exterior connectors - WeatherPak are the best - and they are
OEM for GM. They are sold by Wrangler Power Products in AZ, or
they are sold also by MSD - the ignition people.

With soldered and shrink wrap connections - just dont expect the
wire to flex anywhere near the soldered joint - 'cause it won't,
it will simply break next to the solder joint....

EWong

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Date: Thu, 01 May 1997 12:47:10 -0400
From: "R. W. 'Butch' Stiles" 
Subject: O2 sensor's snap-click connector
To: Toy4x4@tlca.org

Mark D Adrian wrote:
> 
> A couple of trips ago, whilst out in the northeastern corner of AZ on a
> very desolate highway, my ENGINE CHECK light decides to come on. So, to
> make a long story short, I discovered that over time, and a lot of rough
> roads, that the wire going into the snap-click connector off the main
> wiring harness going to the O2 sensor had worn/bent to the point of
> breaking right where the wire goes into the connector's rubber "bushing".
> So, in the field, I was able to solve the problem with a pair of
> needle-nose pliers and some duct-tape (amazing stuff, isn't it?). When I
> got home, Toyota wanted to sell me an entire new harness for some big $s.
> I then went to a car electronics shop and they had no solution either.
> So, I cleaned up the mess I made in the field, soldered the wire as best
> I could to the connector/harness and shrink-tubed it. That's been working
> for months with no problems, but, now I notice other connectors that
> could exhibit the same problem. Does anyone know where you can buy these
> various snap-click connectors that are found on the many sensors of the
> 22RE engine? They need to fit cooperatively with whatever they're mating
> to, e.g. the O2 sensor's connector.
> 
> Mark


Mark,
The best way to do this is to find a truck similar to yours in the bone
yard and just go after it with a pair of wire cutters. This has always
worked for me when I needed a particular connector for a specific
problem or application. In some cases it's possible to release the pins
and open the crimped portion and then re-crimp and solder in new wire.
It's not easy and it's time consuming, but for that "factory" look to
your mods or repairs, nothing can beat it. One caution though, the
sensors operate at very low voltage/current levels, any splicing done
with or around them should be done VERY carefully so as not to upset the
computer. It doesn't take very much to give those ECM's extreme
heartburn. Good luck!
- -- 
Butch Stiles 
rokitman@erols.com
Just as it says, "Rocket Man"

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