Some connectors have a tang lock to hold the connectors together during vehicle operation.

Some tang locks (1) are released by pulling them toward you.

Some tang locks are released by pressing them toward the side (2).

Never pull on the wires to separate the connectors. This will result in wire breakage.

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. Carefully pull the two halves of the connector apart.

Firmly grasp both sides, male and female, of the connector. Ensure that the connector pins and pin holes align. Ensure 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.

Use a circuit tester to inspect 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.

The test probes can not be inserted into the connector wire side of a waterproof connector. Prick the insulation on the wires with a straight pin. Connect the test probes to the straight pin to inspect for connector continuity. Use one side of a connector (1) with the 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 inspect the connector continuity.

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.
3. Pull the wire pin free from the wire side of the connector.

1. Insert a slender shaft into the connector housing open end.
2. Push the tang lock flat, toward the wire side of the connector.
3. Pull the wire with pin free from the wire side of the connector.

1. Ensure that the tang lock is fully up.
2. Install the pin from the connector wire side.
3. Push the pin in until the tang lock closes firmly.
4. Confirm that the connector pin is firmly set in place.

Important: Be careful when handling electrical parts. Do not drop or throw the electrical part, because short circuit or other damage may result.

When installing the parts, be careful not to pinch or wedge the wiring harness.

All electrical connections must be kept clean and tight.

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 block plastic conduit, pull out the desired wire.

2. Cut the wire.

•	Cut 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 ensure that each splice is at least 40 mm (1.5 in) 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.

•	Inspect 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.

4. 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 the 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. Hold them between your thumb and forefinger.

•	Center the splice clip under the stripped wires. Hold the splice clip in place.

-	Open the crimping tool to full width. Rest one handle on a firm flat surface.





-	Center the back of the splice clip on the proper anvil. Close the crimping tool to the point where the back of the splice clip touches the wings of the clip.

-	Ensure that the clip and wires are still in the correct position. Apply steady pressure until the crimping tool closes.

•	Before crimping the ends of the clip, ensure that:

-	The wires extend beyond the clip in each direction.

-	No strands of wire are cut loose.

-	No insulation is caught under the clip.

Important: 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.






5. Solder the clip.

Apply 60/40 rosin core solder to the opening in the back of the clip. 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 duplicate 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.

•	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.

All wires have color-coded insulation.

Wire belonging to a system main harness will have a single color. Wires belonging to system sub circuits will have a colored stripe. Striped wires use the following code to show wire size and colors.