Project 2ZR Vios, part Deux!

[CrankyOldMan]

After lots of frustration and mangled connectors/pins, I finally found some real info on how to remove the smallest pins! There's an OEM wire harness repair document that seems to have all the info I was looking for. It lists the type, size and quantity of terminals for each connector suffix and repair wire part numbers too. I.e. Yaris connector D6 "Windshield Wiper SW Assembly" is part number 90980-12359; suffix 12359 has 4 ea. 0.64 II and 6 ea. 2.3 II female terminals; repair wires are parts 24290 and 12340 respectively.

Props to the author of this article for buying the OEM tools and writing up a review!

Important details:
* Most terminals can be removed with the 1mm-wide tool described in the Yaris EWD. I got a Molex 0638138600 from DigiKey for removing pins from an OBD-II port, seems to work just fine on 90% of the pins I've encountered. At ~$25 it was a steal for an OEM tool.

* Pins used to be sized by decimal inches, now they're metric. There are two different types of some terminals, indicated by "II" after the size. I.e. 0.025 inch pins are now 0.64; there are type 0.64 and 0.64 II, which use different removal tools.

Notes on the 0.64mm terminals:
* 0.64 terminals are most likely TE/AMP/TYCO sourced and are used in sealed connectors like the ECM, evap canister, occupant classification ECU, etc. Some of them may be available through online electronics components distributors like DigiKey, Mouser, Farnell, etc.

* The Toyota OEM parts for removing 0.64 terminals are really expensive:
- 09991-00500 (female terminal) is ~$115
- 09991-00510 (male terminal) is ~$160

* The connector OEM (TE Connectivity) tools are more reasonable but still expensive:
- 1276565-1 looks like 09991-00500, ~$70
- 1579007-8 looks like 09991-00510, ~$90 ** Don't get 1-1579007-8, that's for round terminals in a different connector!**
- 4-1579008-5 also looks like -00510, ~$90

Notes on the 0.64 II terminals:
* 0.64 II terminals are probably Sumitomo sourced and are used in non-sealed connectors. Sumitomo doesn't have any retail/customer-facing options so you're probably not going to get them direct. Take a look around for race car wire harness parts suppliers and see if you can match pictures of what you need.

* The OEM part for removing 0.64 II terminals is also fairly expensive for what it is--a piece of flat spring steel with relatively tight tolerances.
- 09992-01030 ~$55

* Edit: Great picture of a hybrid 0.64 + 2.3 connector on atomic_hoji's 2ZR swap thread!