After a lengthy search, I recently found a source for new wiring harnesses for the 606 engine used in the E300D models--and probably a source for harnesses used in other older Mercedes models as well. I've been looking for about a year for either an NOS or used non-soy based glow plug harness for my 1995 model without luck. I tried a wide variety of Mercedes, independent, and aftermarket parts dealers in the US and overseas, typically asking each contact I called if they could provide me with any other sources if they did not have a harness themselves.

One of the last references I received was for the ADSIT Company, a Mercedes-only supplier of new, rebuilt and used parts, of which I had not previously heard, though I don't have a long history with Mercedes cars. I made contact with a representative named Joe at the firm (800.521.7656) who told me new E300D harnesses were available through a vendor they use. If E300D owners were having a hard time dealing with the price of a new one back in 2008, its going to be even harder to deal with it now. (I did find another source of new harnesses even more expensive!) ADSIT can apparently also supply other wiring harnesses used on these vehicles.

I just finished the installation of the harness and can report it went in without a hitch. Comparing the two harnesses showed both to be of very similar measurements with the new one showing some slightly longer wiring branches. The new harness has all new wiring and plugs, although it appears to be built around a clean but reused plastic support frame. Wire length and plug configuration and size differences make it obvious which plugs go where.

As I noted in a recent post about the harness removal, the replacement requires the installation of different glow plugs, since the connector caps for the original glow plugs are NLA. The new glow plugs (included in the price of the harness) are Bosch 0 250 201 054 and the connectors for them used on this harness are 011 545 85 28.

Here's the comparison between the original and replacement glow plugs showing they are essentially identical except for the connector plugs:

BOSCH 0 250 201 035 (original spec)
•Fitting Depth [mm]: 28
•Port Type: PIN
•to Tightening torque [Nm]: 25
•Tightening torque from [Nm]: 15
•Spanner Size: 12
•Cone Pitch: 63
•Thread Size: M 12 x 1,25
•Length [mm]: 120
•Rated Voltage [V]: 11,5
•Glow Plug Type: after-glow capable
•Glow Plug Type: Pencil-type Glow Plug

BOSCH 0 250 201 054 (replacement glow plug)
•Fitting Depth [mm]: 28
•Port Type: PIN
•to Tightening torque [Nm]: 25
•Tightening torque from [Nm]: 15
•Spanner Size: 12
•Cone Pitch: 63
•Thread Size: M 12 x 1,25
•Length [mm]: 116
•Rated Voltage [V]: 11,5
•Glow Plug Type: after-glow capable
•Glow Plug Type: Pencil-type Glow Plug

The 4mm difference in length is due to the connector end of the new glow plug being shorter; from the 12mm nut down the two are identical. Since the connector for the new glow plug is still available, it does make it possible for people who wish to rewire their harness to do it themselves using the new glow plugs.

Full Disclosure: I've received nothing and have been promised nothing from the ADSIT Company for noting the harness' availability. I've posted this simply as information for those seeking a way to keep these wonderful old cars on the road. I intend to keep driving mine for years...

Regards,
Tom

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What did the new harness run $ wise?

How was the plastic channels on your old harness? If good you should attempt to rebuild it.

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92 e300d2.5t
01 e320
05 cdi
85 chev c10

$1,500. Like I said, not inexpensive, but not the most expensive of the alternatives I've seen when all factors considered.

The plastic channel was in good condition. However, I opted to go with the new one because I couldn't afford to have the car off the road for any length of time. Redoing a wiring harness is not something that can be accomplished quickly, especially if you've not done one before. Some of the plugs on mine would also need to be replaced, including the glow plug connectors and those were NLA.

My thoughts were now you have all the time you need to rewire it.

__________________
92 e300d2.5t
01 e320
05 cdi
85 chev c10

OBG good information. Didn't know they were NLA. Maybe this should be a sticky.

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BENZ THERE DONE THAThttp://www.peachparts.com/shopforum/...c/progress.gif
15 VW Passat TDI
00 E420
98 E300 DT
97 E420 Donor Car - NEED PARTS? PM ME!
97 S500
97 E300D
86 Holden Jackaroo Turbo D
86 300SDL
(o\|/o)

Ha! After that year-long search and the cost, I expect never to have to look at or think about that harness again! I'm totally done with it. And, with a vehicle of this age, I've got other, more compelling, fish to fry. I've been working through a to-do list of projects and have completed a brake system rebuild and flush, wheel bearings, and am half-way through the replacement of all fuel lines with the rest to follow when I can.

Still need to figure out the inoperative cruise control (which will require removal of the intake manifold yet again), the erratic operation of the intermittent wiper setting, and installation of a front air dam which was damaged by the previous owner.

I got talked into buying the car by someone who is a Mercedes fan who sold it to me as a "cult car", wound up not paying very much for it, and have come to love driving this remarkably reliable vehicle and would like to keep as long as I can. And it never needs to go through New Jersey inspection again!

Regards,
Tom

At this high of a replacement cost. Junkyards may be your friend. All you have to do is know how to identify the replacement ones. Most originals where probably all changed out as they tended to disintegrate. Their replacements where probably good enough for the life of the car.

You could've had the Harness:
Redesigned and Hand built by Bavarian Virgins.


Wiring Harnesses - Narragansett Reproductions - Wiring Harnesses and car restoration supplies


Wiring Harness Restoration, Repair, Rebuilding, Customizing


Harnesses Unlimited - custom auto wiring harness

__________________
'84 300SD sold
124.128

Good info OBG, mine wasn't too bad, ended up measuring gauge of wiring used ordered online correct colours and lengths.

Connectors come apart easy enough, each feral has a horizontal hole which the wire then passes though, the center is filled with solder. This can take a while to melt with a regular soldering iron, but it does go eventually.

__________________
David


1996 Mercedes S124 E300TD - 129k - rolling restoration project -

1998 Mercedes W210 300TD - 118k (assimilated into above vehicle)

Barvarian virgins? I wonder how this works. Can you ladies make a harness for me and are all of you virgins? Or can you give me the non virgin discount?


Almost but not quite at that price puts it over the top. I source really expensive parts for some of my local friends and relatives from time to time. Sometimes with good results but not always.