FYI FEELER: Interest in Custom-Made, High Quality Sets of E500E Spark Plug Wires ?

[gerryvz]

Folks,

I'm getting ready to order the necessary parts to create a new set of spark plug wires for my E500. This requires a special MB crimping tool, which I have (MB part number 000 589 55 37 00, list price $608, discounted to $456).

The wires would use quality wire stock, terminals and boots, and would include little "extras" such as spark plug numbers.

At this point in time, I do not know how much each set will cost. However, they will be of the very best quality, and made to order (i.e. correct length) for the M119 engine as used in the W124. I would use only Beru wire, and a mixture of Beru and MB OE parts (rubber boots and such). They would be the correct length wires for each cylinder on the E500E, and would have small numeric markers for each cylinder's wire attached to each wire.

It would be incremental to order additional parts to make additional sets. I'm thinking to start off with a total of TWO sets. That would be ONE set for myself and ONE set available for sale. It is possible I could have enough wire for THREE sets, but definitely for two.

For contrast, a set of aftermarket Karlyn wires for the E500E is around $150, and the favored Beru wire set (the ZEF-635) is $202.58 at PartsGeek.com

MB's Q-4-15-0036 ignition wire set (which last list priced around $500) has been discontinued.

Thoughts -- interest?

Or are folks needing new wires content with the Beru set for ~$200?

 

[gsxr]

I've BT and DT. After finding the Beru set that Trae describes in the link below, I would *not* recommend bothering with a custom-fabricated set, unless you want red-color wire bad enough to pay double for it. The Beru set has near-perfect lengths, within ~1 inch from my custom measurements.

Besides the cost of components adding up to crazy levels (easily over $300 in parts), and difficulty obtaining the metal-jacket plug boots instead of the plastic-orange ones, the labor involved is extensive - particularly the learning curve. The hand crimp tool slightly bends the threaded tip, no matter how you handle the pliers. Each crimp terminal must be straightened out manually and test-threaded into a spare boot with the rubber cut off.

Just buy the Beru set while you can. PG is showing 40 in stock, $202 each plus tax.

FYI - Beru spark plug wire set ZEF-635 | M119 Engine

Hi guys, I had been chasing a misfire on my 93' 500E for a month. I had replaced spark plugs, caps, rotors, and insulators behind the rotors thinking it might have been moisture build up behind the cap. Car ran fine cold, BUT would misfire as soon as it reached operating temperature. Then, I...

www.500eboard.co

 

[gerryvz]

Adding up the costs for the components, it is likely the total cost of a custom made set would be $400+, and that is not marking up any of the components. Just the Beru wire alone is well over $200, and that is only enough to cover two sets of wire (with almost enough wire for a third set left over). So out of the $400+ for a set, just the wire alone would be pushing $100.

That said, I'm going to go ahead and order enough wire and components for TWO sets of custom wires. I'll probably go with the RED Beru wire. So that will leave a set available for someone who wants one.

 

[gsxr]

Sounds good, Gerry. I'd recommend practicing several cuts & crimps before you do the first "real" wire. I also recommend NOT using the factory-specified lengths, if you want the routing to be perfect. I ended up tweaking almost all by plus or minus 0.5-2.0 inches vs spec.

Finally, don't forget to order the assembly lube. I tried using something else (can't remember - silicone spray?) and the threading process was miserable, as the lube would dry before the wire was spun into the boot. I assume the proper lube will help considerably.

 

[gerryvz]

I was actually going to use my existing wires as guides for the new ones, and add approx 0.5-1 inch to each one (if needed, depending on how taut or loose it was in position). Thanks for the pointers.

It would also be feasible to offer a set of wires with the crimped on ends alone, so the existing spark plug connectors and 90-degree rubber boots could be re-used. This would likely cut the price down by over half from the $400+ "turnkey" cost.

 

[RicardoD]

How long do spark plug wires last? What would be the recommended PM interval. I remember when I changed my spark plugs the first time the wires finally gave up. Replaced with Bosch (a bit short in places) and then I think when my engine was out I put in the MB set that I got from Robert Fenton. (need to check my parts stash to see if the MB set is still there).

 

[gsxr]

Top-quality wires can last almost the life of the car. Many go to the graveyard with original wires. This is partly because the wires are solid-core copper wire, not resistance carbon-thread type often used on older domestic vehicles. There have been reports of failures, but they are rare. And if the wires are physically damaged in some way that can also necessitate replacement. If I had to toss a number out, I'd say that after 150-200kmi on the originals, it's probably not a bad investment to replace with new Beru from Trae's post.

I've mentioned it before, but I don't like the commonly-available Bosch wire set with gray wires and orange plastic boots. A couple of my E420's came with these installed by a PO, and I found the gray wire insulation tears far too easily. By comparison, the Beru wire insulation is far more durable. I also wouldn't mess with any other brand of wire, but there are some pretty blue ones from NGK or something, IIRC...

 

[kwontumspeed]

Is the Beru on PG the solid-core copper?

 

[gsxr]

Is the Beru on PG the solid-core copper?

Yup. I think any/all M119 wire sets should have the solid-core wire, or at least I've never heard of any which aren't...

 

[gerryvz]

Finally, don't forget to order the assembly lube. I tried using something else (can't remember - silicone spray?) and the threading process was miserable, as the lube would dry before the wire was spun into the boot. I assume the proper lube will help considerably.

Already have a small bottle of the exact proper lube

 

[gsxr]

Ooo, this stuff? I wanted to buy some, but couldn't stomach the TWENTY-ONE THIRTY-FOUR dollar shipping cost for a $7 bottle, nor could I find $93 worth of other items I needed to get free shipping...

WSP-820 Wire Installation Oil

www.kingsbornewires.com

 

[gerryvz]

Roughing out the costs, it appears that a raw set of wires will be ~$100. This is the Beru wires themselves, cut to the correct length, with the threaded Beru end caps crimped on. Generally speaking, the rubber boots and the metal/rubber spark plug suppressors can probably be re-used, as long as they check out from a resistance point of view.

A "full monty" set with all of the above, plus new rubber boots and metal/rubber 90-degree suppressors (MB part) will be pushing $500.

This is with Beru and MB parts. The biggest cost of this ($300) is the eight 90-degree suppressors (which connect to the spark plugs).

By the way, I can make wires and such for the M117 and M104, as well.

 

[gsxr]

Also, AFAIK, the 90-degree suppressors are only available via aftermarket (Beru). The OE MB items supercede to the new orange plastics.

 

[gerryvz]

Ooo, this stuff? I wanted to buy some, but couldn't stomach the TWENTY-ONE dollar shipping cost for a $7 bottle, nor could I find $93 worth of other items I needed to get free shipping...

WSP-820 Wire Installation Oil

www.kingsbornewires.com

View attachment 96046

Do you mean this?

 

[gerryvz]

Here are a couple of items:

 

[gerryvz]

Seems like not a lot of interest in this, given the availability of the Beru wires. So, I'm going to go ahead and order the parts, and make a set of M119 and M117 wires for myself. The 117 and 119 use the same rubber boots and threaded wire connectors, so I can just increase the numbers I was planning to order.

If there is any interest in this in the future, feel free to contact me privately.

 

[Jlaa]

I've mentioned it before, but I don't like the commonly-available Bosch wire set with gray wires and orange plastic boots. A couple of my E420's came with these installed by a PO, and I found the gray wire insulation tears far too easily. By comparison, the Beru wire insulation is far more durable. I also wouldn't mess with any other brand of wire, but there are some pretty blue ones from NGK or something, IIRC...

When I installed the MB Q-4-15-0036 wire set in late 2016, it came in a MB box but the wires were grey bosch ones with orange plastic boots. They had "BOSCH ULTRA SOMETHING COPPER CORE" in white lettering printed on them.

I did save the original wires though, with the original metal boots. Not sure if the boots can be salvaged or not.

 

[gerryvz]

I see a couple of vacuum elbows not connected on Big Red .... and a dirty engine compartment.

 

[Jlaa]

I see a couple of vacuum elbows not connected on Big Red .... and a dirty engine compartment.

Hah, yeah, that was back in 2016 when removing / replacing valve covers / gaskets / oil tubes / etc.