Repair Procedure

1. Carefully cut the damaged wire out of the harness between the points shown in Figure 1.

2. Obtain replacement stranded wire of the same color and gauge as the original.

3. Cut wire to a length that will allow a 10 mm (3/8 inch) overlap on each end.

4. Strip 10 mm from the ends of the wires to be spliced.

5. Place heat shrink splice over each end of the wire.





6. Position the wires to be spliced so that the exposed conductors overlap each other by 10 mm (Figure 2).

7. Slide the heat shrink splice so that the solder ring is centered over the overlapped conductors.

8. Use a heat gun to heat the splice evenly.
Concentrate the heat on the solder ring first.

CAUTION:
Keep heat gun moving to prevent damage of the splice. Be careful not to damage wire insulation or vehicle interior.

9. Once the solder melts and flows into the wires, heat the ends of the tubing to ensure a good seal.

WARNING:
Allow splice to cool before handling.





10. Inspect the splice. If the splice was heated correctly, the solder ring will have melted completely and the contours of the wire strands will be visible (Figure 3). Some light browning of the insulation is acceptable, as long as the solder joint is still visible.

11. Place the new wire in the harness bundle and tape harness.

12. Test the circuit for proper operation.