1995 ISUZU TROOPER Workshop Manual

Fig. 8-3
• When removing the connector for relay (MR5B
type), unfasten the tang
lock of the connector by
using a screwdriver, then pull the relay out.
(Fig. 8-4)
Relay
~
Fig. 8-4
Connecting the Connector (Fig. 8-5)
Fig. 8-5
CHASSIS ELECTRICAL 8-3
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 connec­
tor together until a distinct click is heard.
Connector Inspection (Fig. 8-6)
OK
Test probe
Fig. 8-6
Use a circuit tester to check the connector for continu­
ity.
Insert the test probes from the connector wire
side. Never insert the circuit tester test probes into the
connector open end
to test the continuity (Fig. 8-7).
Broken
or open connector terminals will result.
NO
Fig. 8-7

8-4 CHASSIS ELECTRICAL
Waterproof Connector Inspection
(Fig. 8-8)
Fig.
8-8
It is not possible to insert the test probes into the
connector wire side
of a waterproof connector.
Use one side
of a connector CD with its wires cut to
make the test. Connect the test connector ® to the
connector
to be tested. Connect the test probes to the
cut wires
to check the connector continuity.
Connector Pin Removal
Connector Housing Tang Lock Type
(Fig. 8-9)
Slender shaft
Tang lock
Housing open pad Pin
Fig. 8-9
Wire
1. Insert a slender shaft into the connector housing
open end.
2. Push the tang lock up (in the direction ofthe arrow
in the illustration). Pull the wire with pin free from
the wire side of the connector.
Pin Tang Lock Type (Fig. 8-10)
Slender shaft
Housing open end
Pin
Fig. 8-10
1. Insert a slender shaft into the connector housing
open
endl.
2. Push the tang lock flat (toward the wire side oft he
connector).
Pull the wire with pin free from the
wire side of the connector.
Connector Pin Insertion (Fig. 8-11)
Tang lock Wire
Pin
Fig. 8-11
1. Check that the tang lock is fully up.
2. Insert the pin from the connector wire side.
Push the pin in
until the tang lock closes firmly.
3. Gently pull on the wires to make sure that the
connector pin is firmly set in place.

Parts Handling (Fig. 8-12)
Fig. 8-12
Be careful when handling electrical parts. They
should
not be dropped or thrown, because short
circuit
or other damage may result.
Cable Harness
--
Xt
Fig. 8-13
1. When installing the parts, be careful not to pinch
or wedge the wiring harness (Fig. 8-13).
2. All electrical connections must be kept clean and
tight.
3. Use a grommet orguardtubeto protect the wiring
harness from contacting a sharp edge or surface
(Fig.
8-14).
CHASSIS ELECTRICAL 8-5
Fig. 8-14
4. Position the wiring harness with enough clear­
ance from the other parts and guard the wiring
harness with a vinyl tube and clips to avoid direct
contact (Fig.
8-15).
', '
~
OK
Fig. 8-15
5. The wiring harness between engine and chassis
should be long enough
to prevent chafing or
damage due to various vibrations (Fig. 8-16).
NO
OK
Fig. 8-16

8-6 CHASSIS ELECTRICAL
SPLICING WIRE
1. 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.
2. 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.
3. 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 proce­
dure on a new section of wire. The two stripped wire
ends should be equal in length.
4. Crimp the Wires
Select the proper clip to secure the splice. To deter­
mine 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 {Fig. 8-17). Then,
center the splice clip under
the stripped wires and
hold
it in place.
Overlap bare wires
Fig. 8-17
-
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 backofthe splice clip touches the wings
of the clip.
Make sure
that the clip and wires are still in the
correct position. Then,
apply steady pressure
until
the crimping tool closes {Fig. 8-18). Fig.
8-18
Before
crimping the ends ofthe clip, be sure that:
The wires extend beyond
the clip in each
direction.
No strands of wire are cut loose, and
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 (Fig. 8-19).
5. Solder
Spice clip
6:~
Fig. 8-19
Align tool with edge of clip to crimp ends of splice
Fig. 8-20

Apply 60/40 rosin core solder to the opening in the
back
of the clip (Fig. 8-20). Follow the manufacturer's
instructions
for the solder equipment you are using.
6. Tape the Splice
Center and roll the splicing tape. The tape should
cover the entire splice.
Roll on enough tape to dupli­
cate the thickness of the insulation on the existing
wires. Do
not flag the tape. Flagged tape may not
provide enough insulation, and the flagged ends will
tangle with the other wires in the harness (Fig. 8-21).
Good (Rolled) Bad (Flagged)
Fig. 8-21
"-"' If the wire does not belong in a conduit or other
harness covering, tape the
wire again. Use a winding
motion to cover the first piece of tape (Fig. 8-22)
Fig. 8-22
CHASSIS ELECTRICAL 8-7