Beru plug lead internals ? (Pics)

[twin plugged targa]

Here are some fuzzy pics of Beru spark plug internals after 2 of them snapped off (brand new)
Anyone any idea what that item is which looks like a fuse? - a fuse perhaps?
what is that component for and why the small spring?

I was removing the plug leads to check for condition and to isolate a missfire and 2 broke the heads clean off straight away!
All cables appear new and in good condition - apart from being broken of course!
Any input appreciated.
Are all old plug leads Bakelite?
these seem very brittle
Thanks
Ben

[ossiblue]

Most likely that is a resistor. Beru plugs have a resistance of about 3Kohms created by the internals. Old connectors are famous for having the connections inside break causing a break in continuity. The only other picture I've seen of the internals shows a series of resistors, not the solid core and the single piece you show. I'm guessing it is a new, improved(?) design. Personally, I've not had a problem with the connector breaking, only a problem with the old connectors losing continuity.

BTW, my older cars use the old style Beru, with the straight connect to the wire. Yours looks like the wire connects 90 degrees to the connector--a later style. That may account for the difference in the internals. Experts will correct or confirm this information.

From the look of the break, my guess is you are pulling the connector off by putting too much leverage on the 90 degree bend--possibly an inadvertent lift that snaps the bakelite.

[Steve@Rennsport]

Originally Posted by twin plugged targa

Anyone any idea what that item is which looks like a fuse? - a fuse perhaps?
what is that component for and why the small spring?

I was removing the plug leads to check for condition and to isolate a missfire and 2 broke the heads clean off straight away!
All cables appear new and in good condition - apart from being broken of course!
Any input appreciated.
Are all old plug leads Bakelite?
these seem very brittle
Thanks
Ben

Those connectors contain a resistor for RFI suppression and thats what you see. The spring maintains tension on the assembly.

These have been troublesome since 1970 due to continuity issues and I try to avoid using them for this reason.

These are made of a phenolic material and simply bakes due to the heat exposure and becomes even more brittle.

[twin plugged targa]

Thanks for the mystery pieces solved,
Which brand of wires would you reccomend?
thanks
Ben

[Gunter]

Steve@Rennsport said it.......... The resistance has to be checked periodically.

I am one of the odd birds that like Beru's.

911.602.315.00 supersedes 911.602.311.00 – Both black connectors will work. (The brown ones may be a different bakelite more sensitive to heat?)

Ignition cables end to end with Beru connectors: ~4000 OHMS resistance.

The long plug connector has ~3k OHMS
The short cap connector has ~1k OHMS

I use an 8mm cable copper-core off the roll and make up a complete harness using the long black Beru's.
To prevent the connectors from breaking due to a solid (frozen) connection to the plugs, I use a dab of high-temp Neverseize on the plug-connections.

Along with checking the resistance periodically, I also check the plugs for correct torque. (They do come loose)

[flatsixjunky]

Magnecors are considered a good choice around here, but I don't know if this holds true for your car, I have an '89.

Read at this:

Choice of Best Spark Plug Wires

Take care.

[twin plugged targa]

Are plug leads with resistors essential?
How would you know if they have them? or not
I have heard a lot of mention about Magnecor cables, or are they more suitable for performance setups?

If I end up with Beru again I will try and avoid the right angled type as it is very easy to pull on the head and 'snap' - as I have done to 2 already!

I will also check the torque on the plugs
regards Ben

[RWebb]

1. no - they are for RFI supression; that can be in the wires if needed

2. measure the resistance with a DMM

3. just plug the word into the search box

[Gunter]

Ben:
All BERU connectors, black or brown, have resistors in them to suppress noise for your radio par example.
Try to unscrew the cable from the broken connector. Does it have the 3mm end-crimp? If the cables are still good, consider just ordering single BERU connectors with a 3mm thread.
Some factory ignition harnesses came with grounded shields to prevent sparks from leaking cables possibly starting an engine fire. Some people prefer this type for safety-reasons.
You don't need resistors in the harness; it's your choice.
You can either make up your own harness or buy a ready-made one; lots of choices but make sure it is designed for your engine because the connectors need the rubber seal to close the hole.
The long BERU's all have the cable connected at an angle, that's not a problem for breakage.
The connectors can be tight on the plug and the trick is to turn them a little left and right while at the same time pulling up.
Then use a little high-temp grease on the plug-tip, or inside the connector-clip, before re-connecting.
When connecting, you want to hear and feel a noticeable snap.

[twin plugged targa]

Thanks Gunter
I did buy some new Beru's but they have a difference 'end clip'
sorry, started a new thread with pics of end clips here:
New Plug leads help needed please!

cheers
Ben