SRS Floor Harness Connector

SRS Floor Harness Connector

NOTE
Repairing the floor harness connector is applicable to all vehicles covered by this TSB and should be performed FIRST.

1. Remove the front seat.





Refer to the Technical Information System (TIS), applicable model year Sienna Repair Manual, for each type of seat assembly:





2. Remove the tape from around the corrugated tubing. Remove the corrugated tubing and discard.





NOTE
Some vehicles may have an additional sleeve protecting the wiring that will need to be removed. The additional sleeve can be discarded.





3. Measure 80 mm (3.15 in.) from the tip of the floor harness connector and cut the wires.





Retain the old floor harness connector for reference.





4. Remove 8 mm (0.32 in.) of insulation from the ends of the 2 floor harness wires.





5. Prepare the new wires with the female terminals.





A. Measure 80 mm (3.15 in.) from the ends of the female terminals and cut the new wires to length.





B. Remove 8 mm (0.32 in.) of insulation from the end of the 2 female terminal pigtails.





6. Install a barrel sleeve onto each of the floor harness wires.





7. Place the sleeve into the 1.25 mm crimp die of the SST.

HINT
Place the sleeve into the SST so that the split in the sleeve is in the half circle of the SST.

NOTE
SST 09042-2C100 is the only tool approved to perform this repair - Do NOT use any other tool to crimp the sleeve.





8. With the sleeve correctly placed in the SST and wire fully inserted into the sleeve, crimp one side of the sleeve in the area shown by closing the handles fully until they release. Crimp the sleeve onto each of the floor harness wires.

NOTE
The SST has a ratcheting mechanism, and the handle will release when the proper crimp has been achieved.

9. Insert the new harness pig tails into the sleeves and crimp using the SST.

NOTE
The new pig tails are color coded to match the existing floor harness.





10. Lightly tug on each connection to ensure that the wire is securely crimped.





11. Install the thermo tubing on each wire.

A. Center the thermo tubing over the center of the barrel sleeve.





B. Using a heat gun, heat the thermo tubing until it shrinks and seals the repaired connection.

NOTICE

^ When using the heat gun, keep the heat gun about 10 mm (0.39 in.) from the thermo tubing.

^ Protect the surrounding areas (i.e., interior panels and carpet) from heat damage.





NOTE
During the sealing process, adhesive may seep from the thermo tubing. This is a normal condition and part of the sealing properties of the thermo tube.

12. Install the new floor harness connector.





A. Confirm the secondary lock is in the half locked position.





B. Install each wire into the new connector until a click is heard and the terminal is fully seated.

NOTE
Use the old floor harness connector as a guide to insert the correct wire into the correct connector cavity.





C. Carefully push the secondary lock until the secondary lock is fully seated.

NOTICE
When pushing the secondary lock in, do NOT damage the terminals.

13. Cut and install 80 mm of new corrugated tubing onto the wiring. Tape the corrugated tubing to hold it in place.