Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1166

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.