Re-use spark plug connectors?

yelcab1 · 12-20-2003, 06:22 PM

Is is possible to remove the spark plug connector on the Porsche set, and re-crimp it on new wires? I like to change the color of my spark plug wires and also lose the metal shieding around the old cables. And, I have a set of new wires laying around with the right Red color.

makaio · 12-20-2003, 06:24 PM

You actually don't need to crimp them, they just screw on and off.

yelcab1 · 12-20-2003, 06:27 PM

So, peel back the small cover, unscrew them, and that's it?

jmohn · jmohn's Garage

Actually, for the SC (and possibly later) models, the connector at the distributor cap has a screw type connector (like a wood screw) that screws into the center wire bundle of the ignition wire. The plug end , however, is a bit more complicated. At the plug end there is a little cap with a threaded stud that must be fitted onto the ignition wire (bare approx. 3/16" of the wire first and fit it into the hollow portion of the stud), this cap is then crimped onto the ignition wire insulation and the stud is crimped onto the wire that was fitted into it. The Beru plug connector then threads onto the stud on this little cap. The caps are available as a Mercedes Benz part (part number: 000 159 14 38). Be aware these connectors are meant to be used with a STRANDED WIRE ignition cable, not the resistance type (graphite or spiral core) cables more commonly found today.

If you choose to re-use the connectors, you should check them with a volt/ohm meter to be sure they're still "good". The distributor end should have approx. 1000 ohms resistance and the plug end should have approx. 4000 ohms resistance. Less reistance isn't too bad but more is a failed (or failing) connector and shouldn't be re-used.

Good luck,

Jerry M
'78 SC

KTL · 12-20-2003, 06:49 PM

The dist. cap/spark plug connector itself screws right into a terminal that is crimped onto the wire. Just hold the wire and twist the connector right off. Should unscrew easily.

So if you want to get new wire and reuse the connectors, you'll need to get new crimp-on terminals for your new wire. The Porsche part # for the crimp-on, threaded terminal is 911.609.310.00

But, these Beru spark plug connectors are known to be troublesome and are expensive to replace- to the tune of $25 ea. They have resistors in the connector that fail. So reusing them is not always a good idea. Replacement wire sets without the Beru connectors are the recommended upgrade to avoid the pesky Beru connector problem. I know Magnecor wire sets have the better connectors (and better terminals and wire according to Magnecor), but I don't know about the others out there.

RoninLB · 12-20-2003, 07:56 PM

Quote:

Originally posted by KTL

But, these Beru spark plug connectors are known to be troublesome

ditto

and sometimes trouble shooting them can be so much fun.