M103 Spark Plug Wire Routing
 

Aaggghhhh! I'm ready to pull the rest of my hair out!

I have tried every possible thing I can think of to get the wires in a format that will allow the plastic strip snap down over them. Don't know if there's anything one can offer toward that end but I will appreciate any suggestions...

https://uploads.tapatalk-cdn.com/201...9a231d8415.jpg

You got to follow the sequence laid out on the distributor cap protection shield. But even then you need to have the mindset of a German born around 1955.

'55 seems a bit late.

Here's an example of proper routing at the distr cap. Looks like Medusa's cowlick.

https://i.imgur.com/TdS8Bss.jpg?1

The wires cannot be bundled like you have them. They need to be laid out flat.
Here is the cap layout.

Ahah!


So there IS a diagram I should have been following....:mad:


It's not like the plastic cover wasn't fitting properly prior to my removal for replacing VC gasket, however, it would appear I've got some work to do :eek:


Thanks guys for setting me straight, and BTW, I was born in '54 so I should have been thinking like a German!


Dale

Having the wires a mess is my #1 103 pet peeve. Those aftermarket wires look to be a little thicker than stock, if so I'm sure it ain't helping. Using a new loom will help a lot, they aren't expensive.

Cables cant have ties, you also can use spray glue to hold them in position prior to putting cover on, and if the diameter of cable is too big they wont fit fyi

Agreed!!!


This new "loom" you speak of, are you referring to the plastic cover for these wires? If yes, I would guess the dealer is likely my best bet or is there another possibility? 'Cause I do need a new one as mine was cracked in the first place. Thanks


Dale

EDIT: Nevermind on that question where to find the part. I Googled the p/n and *voila* - eBay! Done :)

I've never seen this diagram. Mine had been gone for a longer time than I've owned it. Maybe that explains my 'mess' of wires! Thanks for sharing it, I'll use this to reroute them.

Dale

If the leads are to thick they wont fit ,.And the cover wont sit low enough for you to clip the cover in place .Think original are 7mm aftermarket turn in at 8mm and above.

Now that I find myself in this quandary, what are these not-so-old cables good for?


They worked when I first installed them less than a year ago and right at 10K miles. Perhaps they have swollen...? Oh well, I'm not really ready to fork over another $100+ for a set of wires but if the new loom won't fit, I suppose that's my only option. Hmmmm, wonder how much the dealership wants from my bank account for such...:confused:


Dale

You cables look a little bit short and very thick.

I only used Bosch cables on my 103, all other brand fail in a couple of months (including Beru). Bosch has very good cables that are not to thick and very flexible.

I always put the cables on the cap and in the plactic cover on my workbench, not in the car.
That makes it much easier. just close the cover section by section and hold it close with tie-wraps. You can cut the tie-wraps when installing it in the car.
Never use tie-wraps directly on cables.

Rob

Rob, mind sharing where I might find the BOSCH brand? Looked at all the usual places but no gold. Really surprised Pelican doesn't carry them.

Not sure how else to temporarily retain them (wires)....?

Of coarse I don't mind sharing where I buy parts. But since I live in the Netherlands it won't be of much use to you.

Rob

Bosch no longer makes spark plug wires. I contacted them directly and they told me that they will no longer be manufacturing spark plug wires as they are becoming obsolete.

These days it is not very clear who makes what and where.
It is possible that Bosch spark plug wires are now made in the well known peoples republic in the east, but they still sell them (at least in Europe).

The Bosch number is: 0 986 356 332

Rob

Makes complete sense.



Kingsborne will make them. I had them build a set for an E23 745i Turbo that has an inductive pickup on the No 1 wire for feeding the KLR (knock/boost box) cylinder timing information.

You can also choose 7 or 8mm. :):) And pick colors if that is your thing.

FWIW, my pal had a set made for his 400E reusing his old ends. Ran him under $100.

This is the best way IMO, A local mom/pop shop that sells batteries here have this service for battery cables and spark plug cables too. Quite low cost too and their crimping tools are great items from ye-olde american manufacturing.

well if some shop can make the wires then so can the op if he is mechanically inclined. Go to the junk yard ans find a set of wires from a similar car and strip it down to see how its built. then go and buy the materials and make your own. I did this when I could not find any non-resistor spark plugs. I ended up making my own from a set of resistor plugs.

The original wires very rarely fail. It is usually the resistor ends that fail and they can be replaced without replacing the whole wire. The ends unscrew off of the wire.

Ok.

So, I've gotten plenty of information to digest! I'm not being making my own, provided I can find the proper wire at a reasonable cost and find the time - which I think I can around the holidays.

They're has been a suggestion of a source - "Kingsworth" or something of the sort. Is there another couple sources online worth mentioning? There isn't much of a market for used plug wiring but I sure hate to waste these good NGK silicone wires with not more than 15K miles on them...[emoji58]

Thanks
Dale

EDIT: meant to say...

So, I've gotten plenty of information to digest! I'm not beyond making my own, pro.....

As was mentioned above , it appears Bosch long longer makes plug wire sets. A quick internet search reveals that Beru plug wire sets are still available for around $85. I would not hesitate to use Beru products. I also found that the individual parts are still available but are not a good option money wise. The resistor ends list for$22.50 each and the bulk wire is $20 a meter.

If you still have the original wire set you may could repair them but if you need more than 4 resistor ends it would be cheaper to buy a complete set of Beru wires.