Non-SRS Wiring Repairs: Toyota/Lexus

What is a non-SRS wiring repair? It is the repairing of an electrical component that is not part of the supplemental restraints system circuit (usually identified by yellow wire looms). As technology increases on vehicles, so does the number of components that utilize electricity. Many of the sensors and modules are becoming smarter and more sensitive. If the wire is too long, the wrong gauge, or spliced in the wrong location, it can cause malfunctions in the components that it’s powering. Many OEMs have different restrictions and guidelines for repairing wiring that doesn’t control SRS components. On the other hand, there are OEMs that don’t allow wiring repairs at all, so full harness replacement is the only option. Let’s take a closer look at Toyota/Lexus.

To access Toyota/Lexus wiring repair information:

1. Log in to techinfo.toyota.com
2. Click on the TIS tab (top of webpage)
3. Use dropdowns to select the Division, Model, and Year of the vehicle
4. Type General in the Keyword search field
5. Click the Search button
6. Click on the EWD tab

Under the EWD tab, you can typically find the following documents:

• Wire Harness Introduction
• Wire Harness Repair Guidelines
• Terminal And Connector Repair Procedures

These documents provide charts and images that detail with a symbol what damage can be repaired and what damage requires the harness to be replaced. You can also find detailed repair procedures, as well as part numbers for special tools and equipment.

Here is some information that can be found in the above documents, using a 2021 Toyota Corolla as an example:

Per the Wire Harness Repair Guidelines: "Do not repair shielded wiring. Notice: After repairs, shielded wiring performance cannot be guaranteed."

Per the Wire Harness Introduction: "Notice: After any electrical repair is made, always test the circuit by operating the devices in the circuit. This confirms not only that the repair is correct, but also that the cause of the complaint was correctly identified."

Per the Terminal And Connector Repair Procedures: “Inspect the terminal and connector for any deformations or damage.

Reference:

• The terminal and connector are fragile.
• Do not reuse damaged components.
• Check the guideline damage type list to determine whether or not repair is possible."

These are just a few examples of all the helpful information in these documents. It is important to read these documents and service and repair manuals to make sure what repairs can be carried out and where, to achieve a complete, safe, and quality repair.

For additional Toyota/Lexus information, check out the following pages:
Toyota OEM Information
Lexus OEM Information

Additional I-CAR Collision Repair News you may find helpful:
Non-SRS Wiring Repairs
Step-By-Step: Accessing Toyota, Lexus, And Scion Repair Information
Toyota/Lexus/Scion Restraints Wiring
Where Do I Find Other Types Of Information In Toyota/Lexus?

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Related I-CAR Courses

Course Toyota Collision Repair Overview

Course Wiring and Connector Service and Repairs