Wire Repairs - BMW 1999-2005 M3 Service Manual

General
5 of 5
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switch is "open" when the circuit is
interrupted, and "closed" when the circuit is
completed. See
General for electrical troubleshooting.

Wire repairs

Repairs to a wiring harness require special
care to make the repair permanent. The wire
ends must be clean. If frayed or otherwise
damaged, cut off the end. If the wire is too
short, splice in a new piece of wire of the
same size and make two connections.
Use connectors that are designed for the
purpose. Crimped-on or soldered-on
connectors are best. Crimp connectors and
special crimping pliers are widely available. If
soldering, use needlenose pliers to hold the
wire near the solder joint and create a "heat
dam". This keeps the heat and the solder
from traveling up the wire. Always use a
solder made specifically for electrical work
(rosin core).
Note:
Twisting wires together to make a repair is
not recommended. Corrosion and vibration
will eventually spoil the connection and may
lead to irreparable damage to sensitive
electronic components.
Insulate the finished connection. Electronics
stores can supply heat-shrinkable insulating
tubing that can be placed onto the wire
before connecting, slid over the finished
joint, and shrunk to a tight fit with a heat gun
or hair dryer. The next best alternative is
electrical tape. Make sure the wire is clean
and free of solder flux or other
contamination. Wrap the joint tightly to seal
out moisture. See
General for more information.
600 Electrical System–
600 Electrical System–
2/25/2009 10:08 PM