ID a power connector (Toyota Prius & RAV4 EV, Nissan Leaf, and Tesla Model S related)

asavage · Post by **asavage** » Sun Jul 30, 2023 4:02 am

I'm trying to ID this connector, as used on these vehicles:

Toyota RAV4 EV 2013-2014, G9081-0R013

: Toyota RAV4 EV 2013-2014, G9081-0R013

Toyota RAV4 hybrid 2018-on (ref):

: Toyota RAV4 hybrid, 2018-on ?

Toyota Prius 2012-2017 A/C compressor harness 82122-52070 (ref.):

: Toyota Prius, 2012-2017 A/C harness

Nissan Leaf 2018-2023 ? A/C compressor harness 297A6-5SA0A (ref.) or 2012-? 297A6-3NA0A (ref.):

: Nissan Leaf 2018-2023 ? A/C compressor harness 297A6-5SA0A

I'd like to build a short harness that uses this connector, and because I'm interfacing with another unit that would be very difficult to obtain its terminals, and I'm trying to avoid a butt splice, this connector shell and terminals is what I'm seeking. Worst case, I buy one of the used harnesses above and butt-splice, but I'd prefer to do it cleaner.

---
[later]
Subaru 2019-22 Crosstrek Hybrid battery pack uses this connector.

Tesla Model S A/C compressor (2012-at least 2015) uses this connector on the harness that connects to the compressor, harness No. 6007383-00-C. KET (Korea Electric Terminal Co.) appears to be the harness mfgr.

Connector Experts sell it as a Toyota A/C compressor connector, their SKU CE2355-1, for $96, though not the terminals.
https://connectorexperts.com/i-25538322 ... essor.html

I suspect the female terminals in this shell are Sumitomo 8100-1555, which accepts a tab of 4.8mm and whose external dimensions are 6mm W x 3.8mm H x 18mm long; those dims match the terminals on the Toyota Prius etc. A/C harness above. A mismatch is that that terminal is rated for maximum of 3mm², which is well below what I think is needed for 40A (6mm²).

[later]
Toyota 82824-0R330 is the female connector shell only. Toyota doesn't sell terminals for a harness repair, they sell a pigtail with the terminal attached, and -- strangely -- there's no part No. listed for this connector's field replacement pigtail, though there are for the other connectors in this harness; go figure.

: Toyota 82824-0R330 (F) / 82824-0R320 (M)

This shell is NLA from Toyota in the US, but apparently available from https://www.fitinpart.sg/index.php?rout ... d=51295085 Fitinpart canceled my order, naturally: it's NLA.

asavage · Post by **asavage** » Wed Aug 09, 2023 1:04 am

Unable to locate the connector/terminal specs, I instead purchased a Toyota Prius 2010-2012 A/C wiring harness 82122-47010 via eBay for $31, which is long enough that I can cut off the A/C compressor end of the harness to mate with the RAV4 EV’s charge harness instead of the J1772 port’s harness.

It's ugly/dirty but at least $30 less expensive than a nicer one, and I'll be discarding the split loom anyway, so I'm hoping the connector will clean up with a bit of effort.

: Toyota Prius 2010-2012 A/C wiring harness 82122-47010

: Toyota Prius 2010-2012 A/C wiring harness 82122-47010

[later]

That Prius A/C harness arrived, I cleaned it up, and it looks to work OK . . . up to maybe 20A. It's shielded wire for use with the A/C compressor, so its OD implies maybe 10 AWG, but it's actually 12 or 14 AWG when stripped of the shielding, so it won't work for my use case, where I need 40A continuous.

asavage · Post by **asavage** » Tue Aug 29, 2023 2:30 am

asavage wrote: ↑Sun Jul 30, 2023 4:02 am I suspect the female terminals in this shell are Sumitomo 8100-1555, which accepts a tab of 4.8mm and whose external dimensions are 6mm W x 3.8mm H x 18mm long; those dims match the terminals on the Toyota Prius etc. A/C harness above

The Prius A/C harness' terminals have imprinted marks, "LK5" and "N3"

The logo looks to be Sumitomo's:

The terminals in the Toyota RAV4 EV Charge Inlet, connector ID "jh1", which is rated for 40A continuous, have slightly larger gauge wire than the Prius A/C harness (probably uses ~12A continuous), and have similar markings, "LKK" and "N1":

I can find no further information about these terminals, but I still suspect they're Sumitomo's.

asavage · Post by **asavage** » Tue Sep 05, 2023 12:02 am

: Sumitomo terminal 8100-1555 (copper) & 8240-4932 (brass)

I've got some of the Sumitomo 8100-1555 (copper) ones coming from China [later: these appear to be clones, as the ones I received do not have the embossed Sumitomo logo], but I also ordered some 8240-4932 (brass) ones from corsa-technic, just to try the fit a bit sooner, and they arrived yesterday.

: Sumitomo terminal 8240-4932 (brass)

I pretend-crimped one so that the sides would fit in the terminal cavity:

: Sumitomo terminal 8240-4932 (brass) prepared for insertion into Mystery Connector's shell

They fit the mystery connector shell perfectly, and they lock into place as expected.

: Sumitomo terminal 8240-4932 (brass) inserted into Mystery Connector's shell

They've also the Sumitomo logo, as the others.

: Sumitomo terminal 8240-4932 (brass), showing the embossing and Sumitomo logo

: Sumitomo terminal 8240-4932 (brass), showing the embossing and Sumitomo logo

As Sumitomo TS-Series terminals fit this shell, it's reasonable to assume that it's a Sumitomo-produced shell.

I've sent inquiries with pictures etc. to a couple of places that say that they specialize in Sumitomo connector ID; neither have deigned to reply, and it's been >1 week.

Connector ID
Some service site that's a front-end for Ballenger Motorsports