Technician Safety Information

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.




^ When removing the connector for relay (MR5B type), unfasten the tang lock of the connector by using a screwdriver, then pull the relay out.




Connecting the Connector
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 hut 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.




Never insert the circuit tester test probes into the connector open end 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 (2) 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
1. Insert a slender shaft into the connector housing open end.
2. Push the tang lock up (in the direction of the arrow in the illustration). Pull the wire with pin free from the wire side of the connector.




Pin Tang Lock Type
1. Insert a slender shaft into the connector housing open end.
2. Push the tang lock flat (toward the wire side of the connector). Pull the wire with pin free from the wire side of the connector.




Connector Pin Insertion
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
Be careful when handling electrical parts. They should not be dropped or thrown, because short circuit or other damage may result.

Cable Harness




1. When installing the parts, be careful not to pinch or wedge the wiring harness.
2. All electrical connections must be kept clean and tight.




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 and clips 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.