Broken electrical connector

This is probably a generic problem, not just for a 5th Gen 4Runner, but that's where the problem occurred, so here it is.

I was changing my spark plugs, and presumably screwed up a bit while disconnecting the electrical connector from the secondary air injection system. Three of the wires became separated from the connector. Is there a way to repair this, or do I need to go get a replacement connector, and splice some wires? I was thinking perhaps I could just shove the wires back into each one's appropriate connector hole, but am unsure if that would work. Any thoughts are appreciated.

This issue is presumably causing me to get a P2438 code.

 

You need to get the pin out and re attach, I've never done it before but there are plenty of YouTube videos. Did you by chance pull the wires to disconnect the connector?

 

@thomrose524 Well that's a bummer. The thing is with those sealed connectors is that getting the pins back out (even when they are attached to the wire) is extremely hard if you don't have the right sized tool. You are better off getting the repair terminals and a new connector from Toyota and splicing it in (this is coming from someone who hates splicing). Don't try to solder them back in to the existing terminal. The solder joint will fatigue and break at some point due to the vibration of the motor/chassis. This is why all automotive connectors/terminals are mechanical crimps. You can splice/solder in the wire harness itself, but I would use a mechanical crimp myself. Make sure to give it enough strain relief and stagger the splice locations so you don't end up with a bulge in the harness at the splice location.

The Connector part number is 90980-12292 (Confirm this by looking at the back of the connector for the -12292. Almost all connectors start with 90980- with the last 5 being on the connector housing somewhere).

The Terminal repair part number with be 82998-24260. This will come with the terminal, seal, and 6" of wire pre crimped.

Confirm these are correct with your local dealership. Prepare for sticker shock on what each repair terminal will cost.

Here's the wiring diagram for the air injection pump connectors just in case.

 

I may have, though I certainly know better.

 

Thank you!! Depending on what the dealership says the price is, I might try to find a replacement at the junkyard, or from someone parting out.

 

12.00 for the connector
20.00 for each Terminal, Repair W/W

 

All good buddy. We’ve all been there. Disconnect the battery whenever working on electrical. I made that mistake once. $900 later and two weeks at the Acura dealership and it was fixed. All because I didn’t disconnect the battery