Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1476

8-4  ELECTRICAL-BODY AND CHASSIS

NOTES FOR WORKING ON ELECTRICAL ITEMS

BATTERY CABLE

Disconnecting the Battery Cable
1. All switches should be "OFF" position.

2. Disconnect the battery ground cable.

3. Disconnect the battery positive cable.

CAUTION:
It is important that the battery ground cable be
disconnected first.
Disconnecting the battery positive cable first can result in
a short circuit.

Connecting the Battery Cable

Follow the disconnecting procedure in the reverse order to
connect the battery cables.
CAUTION:
Clean the battery terminal and apply light coat of grease to
prevent terminal corrosion.

CONNECTOR HANDLING

Disconnecting the Connectors

Some connectors have a tang lock to hold the connectors
together during vehicle operation.
Some tang locks are released by pulling them towards you 

1

.

Other tang locks are released by pressing them forward 

2

.

Determine which type of tang lock is on the connector being
handled.

Firmly grasp both sides (male and female) of the connector.
Release the tang lock and carefully pull the two halves of the
connector apart.
Never pull on the wires to separate the connectors.
This will result in wire breakage.

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.