Hi

Attached the Engine Wire Harness 202 540 3132. The insulation falling apart after 10 yr, some exposed are touching each other.

What type wire should I use? Is it by the gauge or the amps? I went to autobarn, repco & supercheap auto their automotive wire are firmer unlike dicksmith, tandy, jaycar, more electronic. May not be heat resistant.

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In general, most MBZ wiring up to 16 amps is 18 gauge, stranded copper. Hot leads directly from the fuse panel, electric windows, sliding roofs, etc. use heaver (16 gauge I believe).

I've just come back from Autobarn & bought 10amp=3mm and 15amp=4mm various colors wires. When I ask about "gauge", they dont know,they work in mm instead. Hope the 3 & 4 mm is confirm equivalent of 16 & 18 gauge over there? He said it suitable for engine/heat resistant.

I will need to find or order the fibreglass tapes (very dear $5/meter) for wirings near the engine or intake manifold.

Thanks

If I remember correctly, 18 gauge translates to .75mm

Also the person at Autobarn said as long as the wire is above its specs that shouuld be fine, but not lower than spec. Can I just physically cut & match the copper strain thickness with the ones I bought & cut and paste so to speak.

If it 0.75mm then the ones I bought is OK?

Your shop manual will call out all the correct guages on the wiring diagrams, and if you match the wire size visually with equal or larger replacement wire, you'll be fine.
If you can spare the time, you'll get better wire and lots of color variety from a junk yard car than most auto supply stores. If you are real lucky, find a Mercedes to pull from. Most yards will practically give you the wire, since no one thinks to use it....but of course, ask before cutting out of the donor.
I used the entire harness from a Mercedes years ago for my street rod, mainly because it was all but free, I had a Benz that matched the donor at the time, and the wiring diagram was already done.

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1986 560SL
2002 Toyota Camry
1993 Lexus

Rmt6668,
What is your plan ?
Fixing just the ends of each wire ?
Are you assuming that the invisible part is Ok?
Jorge
(whose W202 seems to be out of the bad years - but, just in case...)

Thanks. Already begun replacing the wires between connectors. The connectors all seems OK & no need to replace. Started on the Fuel Injection & the wires are defintely BAD. Then found below this harness is the Coil Packs Harness which is also very BAD (touching), will take this later. One thing at a time.

I change the wirings using any color I can get a hold on, rather than its original color.

Can some 1 confirm its fine to use bigger gauge or mm wiring replacement?

Finally on one of connectors, it has 4 wiring whose insulation are gone. Is there a plastic (plus shape) to slot betweem them , like a divider, after I heatshrink these wires?

Definitely there is no problem with wires better than stock (bigger diameter), provided you can manage its placement, flexibility, etc.
You are a hero!
Jorge

You also have to make sure the insulation has the proper temperature rating. Radio wire isn't good enough.

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95 E320 Cabriolet, 159K

Thanks. I bought specially from Automotive retailer & also bought PVC flexible tubing all over to protect from heat & mishandlling. This is the pic, picking up new plugs & its all done.

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