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Information on buying and installing new ignition wires - Beru
- Thread starter Glen
- Start date
Re: New ignition wires - Beru
Some time ago Clark told me he had sold his spark plug wire tooling (To Gerry IIRC)
I bought Bremi leads and found them to be OEM quality. There are pics in my owners thread. Also- see this post recently about another source (Not vouching for these leads- could be a gamble at that price)
http://www.benzworld.org/forums/w124-e-ce-d-td-class/#/forumsite/20548/topics/2671874?page=1
Some time ago Clark told me he had sold his spark plug wire tooling (To Gerry IIRC)
I bought Bremi leads and found them to be OEM quality. There are pics in my owners thread. Also- see this post recently about another source (Not vouching for these leads- could be a gamble at that price)
http://www.benzworld.org/forums/w124-e-ce-d-td-class/#/forumsite/20548/topics/2671874?page=1
Re: New ignition wires - Beru
As mentioned back in post #38, I made some of my own wire sets a few years ago. I don't have the tool, I borrowed it to build the sets, and returned it. Bottom line, it was a NIGHTMARE of a job. You'd think it would be easy, but it takes quite a bit of practice. I doubt anyone would be willing to sell sets for under $200 now. And, the Beru metal 90° ends are NLA; and would have cost an additional $200-$250 on top of the wires.
Also keep in mind that MOST of the time, the M119 does not need the wires replaced. They are solid copper-core wires, not carbon-core resistor wires like older American cars. The OE Mercedes wires are often still 100% functional even after 25 years. If there is no arcing due to failing insulation... I'd just test the ends (should measure 2000 ohms, ±20% or so) and make sure the ends aren't bad. Keep in mind that the OE wires have the threaded wire fittings; but many aftermarket wire sets do not unscrew. If an aftermarket wire set end is bad, you may need to replace the complete wire, or the entire set.
Anyway - the commonly-available Bosch gray wires have fragile insulation. I'm not sure if Beru sets are still available. I'd consider going with the OE set mentioned back in post #26... these include new-style plastic plug ends. Whatever you do, please don't buy the $75 Chinese sets off eBay!
As mentioned back in post #38, I made some of my own wire sets a few years ago. I don't have the tool, I borrowed it to build the sets, and returned it. Bottom line, it was a NIGHTMARE of a job. You'd think it would be easy, but it takes quite a bit of practice. I doubt anyone would be willing to sell sets for under $200 now. And, the Beru metal 90° ends are NLA; and would have cost an additional $200-$250 on top of the wires.
Also keep in mind that MOST of the time, the M119 does not need the wires replaced. They are solid copper-core wires, not carbon-core resistor wires like older American cars. The OE Mercedes wires are often still 100% functional even after 25 years. If there is no arcing due to failing insulation... I'd just test the ends (should measure 2000 ohms, ±20% or so) and make sure the ends aren't bad. Keep in mind that the OE wires have the threaded wire fittings; but many aftermarket wire sets do not unscrew. If an aftermarket wire set end is bad, you may need to replace the complete wire, or the entire set.
Anyway - the commonly-available Bosch gray wires have fragile insulation. I'm not sure if Beru sets are still available. I'd consider going with the OE set mentioned back in post #26... these include new-style plastic plug ends. Whatever you do, please don't buy the $75 Chinese sets off eBay!
Re: New ignition wires - Beru
Good to know that it's not a cake walk and it makes me more grateful. Wish I could have got one of those last old-stock ones. But I've got a life-time of spare metal connectors. I thought about just sorting through them and put together a nice set, but at the time opted to go new. Clark's set is very nice with the OEM numbers on each wire.
My car I'm convinced they were replaced with a Bosch set(twice) in an attempt to end the lean-idle stumble. Got a full-set of ignition components ready except the wire tray for the wires.
Michael
Good to know that it's not a cake walk and it makes me more grateful. Wish I could have got one of those last old-stock ones. But I've got a life-time of spare metal connectors. I thought about just sorting through them and put together a nice set, but at the time opted to go new. Clark's set is very nice with the OEM numbers on each wire.
My car I'm convinced they were replaced with a Bosch set(twice) in an attempt to end the lean-idle stumble. Got a full-set of ignition components ready except the wire tray for the wires.
Michael
Re: New ignition wires - Beru
Hi guys, I got a hold of Mark Robinson (MarkRobinson) on rennlist. Mark is still willing to do custom red/blue beru wire sets for approx 150 clams. Mark and I share an interest in redesigned 928 porsche upholstery refined by a gentleman by the name of Paul Champagne out of Corpus Christi TX in our respective P-cars.
Anyways, gsxr, you mention different wire lengths are mentioned in the EPC dpendending if you use the early Beru 90* plug connectors or the late orange Bosch 180* connectors.
i would like to source 8 of the Beru 90* connectors and ask Mark to make wires with the length needed. Do anyone have measurements for both types of sets? We could archive this valuable info for the future.
Mark seems to only have the dimension of the wires used with the later w124.036 M119 engine that uses the 180* orange connectors (as shown by in Glen in post #1). I would like to duplicate Gsxr's wire lengths in post #38.
thank you.
Michael, the stock length wires for the early 90° plug boots are made such that the front plug on each side (#1 and #5)are several inches too long, and get wrapped around a neighboring plug. This is because otherwise, it is difficult to remove the plug boot, due to not enough slack in the wire. The later "orange" plastic plug boots can use shorter wires.
Note that the early-style 90° plug boots use different wire lengths than the late-style plastic orange plug boots shown on Glen's engine. The lengths for both are in the EPC. There is an engine number break for early vs late which seems to have occurred in mid-1994 model year production. (?)
The plastic wire trays have numbers in them so you know which plug wires go in each 'valley' in the tray.
Length/fit will depend on the plug boot style. The early-style 90° plug boots use different wire lengths than the late-style plastic orange plug boots shown on Glen's engine. You need to check what's on your car and get the appropriate set. And measure the plug boot resistance to see if they are still around 2k ohm.
Yes, with coil wires. Don't forget you should to buy the ends too, which are a bit spendy. It's a shame the wire only comes in 25m spools, since you end up with a bunch of excess and only two sets.
Remember that the later "orange" plug boots use different wire lengths compared to the original ones with a 90° fitting on top.
Hi guys, I got a hold of Mark Robinson (MarkRobinson) on rennlist. Mark is still willing to do custom red/blue beru wire sets for approx 150 clams. Mark and I share an interest in redesigned 928 porsche upholstery refined by a gentleman by the name of Paul Champagne out of Corpus Christi TX in our respective P-cars.
Anyways, gsxr, you mention different wire lengths are mentioned in the EPC dpendending if you use the early Beru 90* plug connectors or the late orange Bosch 180* connectors.
i would like to source 8 of the Beru 90* connectors and ask Mark to make wires with the length needed. Do anyone have measurements for both types of sets? We could archive this valuable info for the future.
Mark seems to only have the dimension of the wires used with the later w124.036 M119 engine that uses the 180* orange connectors (as shown by in Glen in post #1). I would like to duplicate Gsxr's wire lengths in post #38.
thank you.
Re: New ignition wires - Beru
I have NO info on the lengths for the plastic 180° connectors, other than what is in the EPC. Never built a set, never figured out if stock lengths were ok or not.
In either case, it is critical to get the correct wire for each cylinder, and have them routed correctly in the X-tray. If you don't have them all in the correct place, they won't fit well at all.
I only figured out custom lengths for the 90° boots. This is really picking nits, you can use the stock lengths without any issues.
I have NO info on the lengths for the plastic 180° connectors, other than what is in the EPC. Never built a set, never figured out if stock lengths were ok or not.
In either case, it is critical to get the correct wire for each cylinder, and have them routed correctly in the X-tray. If you don't have them all in the correct place, they won't fit well at all.
Re: New ignition wires - Beru
Right exactly ---- sorry for making myself unclear ---- May I ask if you have written down those custom lengths for the 90* boots? I would like to pickup a bunch of 90* boots have have Mark make a set of red wires.
Many Many Thanks.
Right exactly ---- sorry for making myself unclear ---- May I ask if you have written down those custom lengths for the 90* boots? I would like to pickup a bunch of 90* boots have have Mark make a set of red wires.
Many Many Thanks.
Re: New ignition wires - Beru
I did this years ago... not sure if I still have the info available.
I believe I gave the custom length info to Clark and he may have used those for his custom sets; try contacting him and see if he has the numbers handy. Were you able to find a source for the 90° Beru plug ends?
I did this years ago... not sure if I still have the info available.
I believe I gave the custom length info to Clark and he may have used those for his custom sets; try contacting him and see if he has the numbers handy. Were you able to find a source for the 90° Beru plug ends?
Re: New ignition wires - Beru
Done! Screen shot attached. Footnote 026 = early/90° ends, footnote 027 = late/180° ends.
Attachments
Re: New ignition wires - Beru
Above and Beyond! Thank you.
I've annotated it with this infographic here --- perhaps this can also go to the right knowledgbase or w124 site for further archived reading.
PS Clark said he will dig up his wire length info.
At the same time I will ask Mark Robinson to confirm his wire length info.
Above and Beyond! Thank you.
I've annotated it with this infographic here --- perhaps this can also go to the right knowledgbase or w124 site for further archived reading.
PS Clark said he will dig up his wire length info.
At the same time I will ask Mark Robinson to confirm his wire length info.
Re: New ignition wires - Beru
Jason, I sent you an email, let me know if you don't receive it.
I also added some miscellaneous info to post #39 about the fun of assembling new wires+boots, and replacing other ignition components at the same time.
Jason, I sent you an email, let me know if you don't receive it.
I also added some miscellaneous info to post #39 about the fun of assembling new wires+boots, and replacing other ignition components at the same time.
I believe so, yes, the wires have to connect to the correct coil.Dumb question- does it matter which of the 2x coil packs you plug the King leads into?
Correctomondo clips are accounted for and going on shortly
I have over 100 photos taken as the old motor came out so I know exactly where every original clip and fastener came from. That's the sort of sh#t that keeps me awake at night
