Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1062

ELECTRICAL-BODY AND CHASSIS  8-5

Connecting the Connectors

Firmly grasp both sides (male and female) of the connector.
Be sure that the connector pins and pin holes match.
Be sure that both sides of the connector are aligned with each
other.
Firmly but carefully push the two sides of the connector
together until a distinct click is heard.

Connector Inspection

Use a circuit tester to check the connector for continuity.
Insert the test probes from the connector wire side.

CAUTION
Never insert the circuit tester test probes into the
connector open side to test the continuity.
Broken or open connector terminals will result.

Waterproof Connector Inspection

It is not possible to insert the test probes into the connector
wire side of a waterproof connector.
Use one side of a connector 

1

 with its wires cut to make the

test.
Connect the test connector to the connector 

2

 to be tested.

Connect the test probes to the cut wires to check the connector
continuity.

Connector Pin Removal
Connector Housing Tang Lock Type

1. Insert  a  slender  shaft 

3

  into  the  connector  housing  open

end 

4

.

2. Push the tang lock 

5

 up (in the direction of the arrow in the

illustration).

Pull  the  wire 

6

  with  pin 

7

  free  from  the  wire  side  of  the

connector.

8-6  ELECTRICAL-BODY AND CHASSIS

Pin Tang Lock Type

1. Insert  a  slender  shaft 

3

  into  the  connector  housing  open

end 

4

.

2. Push  the  tang  lock 

8

  flat  (toward  the  wire  side  of  the

connector).

Pull  the  wire 

6

  with  pin 

7

  free  from  the  wire  side  of  the

connector.

Connector Pin Insertion

1. Check that the tang lock 

8

 is fully up.

2. Insert the pin 

7

 from the connector wire side 

9

.

Push the pin in until the tang lock closes firmly.

3. Gently pull on the wires 

6

 to make sure that connector pin

is firmly set in place.

Fuse Replacement

The replacement fuse must have the same amperage
specification as the original fuse.
Never replace a burn out fuse with a fuse of a different
amperage specification.
Doing so can result in an electrical fire or other serious circuit
damage.

Parts Handling

Be careful for parts handling and any part should not be
dropped or thrown, otherwise short circuit or disorder may
result.

Wiring Harness

1. When assembling the parts, be careful not to bite or wedge

the wiring harness.

2. All  electrical  connections  must  be  kept  be  kept  clean  and

tight.

ELECTRICAL-BODY AND CHASSIS  8-7

3. Use a grommet or guard tube to protect the wiring harness

from contacting a sharp edge or surface.

4. Position the wiring harness with enough clearance from the

other parts and guard the wiring harness with a vinyl tube to

avoid direct contact.

5. The wiring harness between engine and chassis  should  be

long  enough  to  prevent  chafing  or  damage  due  to  various

vibrations.

8-8  ELECTRICAL-BODY AND CHASSIS

SPLICING WIRE

Open the Harness

If the harness is taped, remove the tape.
To avoid wire insulation damage, use a sewing "seam ripper"
(available from sewing supply stores) to cut open the harness.
If the harness has a black plastic conduit, simply pull out the
desired wire.

Cut the wire

Begin by cutting as little wire off the harness as possible.
You may need the extra length of wire later if you decide to cut
more wire off to change the location of a splice.
You may have to adjust splice locations to make certain that
each splice is at least 1-1/2" (40 mm) away from other splices,
harness branches, or connectors.

Strip the insulation

When replacing a wire, use a wire of the same size as the
original wire.
Check the stripped wire for nicks or cut stands.
If the wire is damaged, repeat the procedure on a new section
of wire.
The two stripped wire ends should be equal in length.

Crimp the Wires

Select the proper clip to secure the splice.
To determine the proper clip size for the wire being spliced,
follow the directions included with your clips.
Select the correct anvil on the crimper.
(On most crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them between
your thumb and forefinger.
Then, enter the splice clip under the stripped wires and hold it
in place.

• Open the crimping tool to its full width and rest one handle

on a firm flat surface.

• Center  the  back  of  the  splice  clip  on  the  proper  anvil  and

close  the  crimping  tool  to  the  point  where  the  back  of  the

splice clip touches the wings of the clip.

• Make  sure  that  the  clip  and  wires  are  still  in  the  correct

position. Then, apply pressure until the crimping tool closes.

Before crimping the ends of the clip, be sure that:
• The wires extend beyond the clip in each direction.
• No strands of wire are cut loose.
• No insulation is caught under the clip.
Crimp the splice again, once on each end.
Do not let the crimping tool extend beyond the edge of the clip
or you may damage or nick the wires.