Looking for a connector...

I’d be delighted to be proven wrong, but you probably can’t buy the complete female connector in small quantities, though you can get individual terminals, and I’m afraid the male connector exists only in a version intended for printed-circuit board mounting, not for wire-to-wire use like you propose.

The Electrical Wiring Diagram for the Prius c shows, in the Part Number of Connectors section, that G59 is a 30-position connector on the Main Body ECU, with part number 90980-12909, but it also says, “Not all of the above part numbers of the connector are established for the supply,” which seems to be the case for this connector housing: it’s not available from Toyota as a service part, in the U.S. or in Japan.

Toyota doesn’t sell terminals. If a connector is damaged, you’re supposed to splice on a repair wire (pigtail) with a pre-attached terminal. This avoids the need to have tools to crimp every size and kind of terminal, and it eliminates reliability issues with field crimping. For some kinds of terminals, there simply is no application tooling available for service (as opposed to factory) use. If a connector housing is damaged, and it’s not sold as a service part, you’re supposed to buy the complete wire harness, which as you mentioned, can be very expensive. Toyota’s Wire Harness Repair Manual (PDF) is out of date, but it has other useful information about their approach to repair.

The EWDs for other vehicles that use the 90980-12909 connector say that it takes two types of terminals. For what Toyota calls the “0.5 (Non-waterproof)” type, the repair wire is 82998-47010, or 82998-47020 if gold plating is required, and for the “0.5 W (Non-waterproof)” type, the repair wire is 82998-47030. These are all 160 mm long and are attached with blue splice sleeves, 82999-12020. Note that these are parallel splices, similar to TE Connectivity PLASTI-GRIP 34133, not the butt splices often found in generic kits.

You can buy the 0.5 receptacle contacts (female terminals), but please know that they are tiny—they are the smallest terminals used on the car, and the “0.5” designation comes from the width of the mating tab, which is 0.5 mm, or 0.020 inches. They are also made to be applied by automated factory equipment; even with a high-quality hand crimping tool like the Hozan P-707, you may not get good results every time.

My source for the terminals is hi-1000.com in Osaka; if you don’t get the Japanese pun in the name, you might be more comfortable with their store in English, hi-1000ec.com. Their part number is F020-TE-03505, and the price is 25 cents each. I bought some, and they appear, from the TE logo and “L” size mark, to be TE Connectivity 1827855-2. More importantly, under casual inspection with a loupe, they seemed to have the same dimensions as the terminals on the Toyota 82998-47010 and 82998-47030 repair wires in my spares kit.

These terminals are part of TE’s 0.50 Connector Series, which if the video on that page is a guide, seems to have been developed mainly for wire-to-board applications. Looking though the catalog (PDF), I don’t see that wire-to-wire versions of the male connector exist in that series at all.

For the female connector, page 4 of the catalog has an overview, and Instruction Sheet 411-78268 has the details, of how the 30-position connector housing is built up from a lock (latch) housing (1903614) and three rows of receptacles (1903615, 1903608, and 1903611). Two of those (’14 and ’11) are in stock at Mouser, but the others don’t seem to be available in small quantities.

 

Great info. Possible pull from a recycling yard?

 

You’re most welcome. Have you checked if the circuits you need might be accessible at another connector, perhaps of a different series for which parts are more readily available?

Yes, but that just gets you a female connector like the one already on the car. For @br0keit's original idea—which is, by the way, exactly what I’d do in this situation if the parts were available—you also need the mating connector, which isn’t used on the car and TE doesn’t list in their catalog.