How to repair a D Jetronic wiring harness using correct plugs, boots and crimps.

This is a detailed video showing how to repair and potentially make a Bosch D Jetronic wiring harness.
The protective rubber boots on many cars have long since perished causing the underlying wires to harden and crack due to excessive heat. This video shows how to remove the plastic plugs and reinstall new rubber boots.
The video shows where to buy the protective rubber boots, correct crimps and plastic plugs together with the correct tools. Using good quality precision tools is essential and we show you what tools you will need and how to use them.

[@Nilfaultfound22]

Thanks Mike (and thanks @TonyLiveTV). Always so much great information. I popped back last weekend and took the 560 down the Cheddar Gorge. It was nice enough to have the top down. Very happy day before heading back to Brazil :)

[@MikesMercsandothercars]

I bet the car sounded quite nice in that Gorge. See you in the summer. Mike

[@ronalddean3630]

Wow, excellent work Mike; like surgery! It is amazing to me how so many tiny parts/connections must be in good order to ensure good operation of the vehicle overall. Does the 85 380SL use the same set-up? Ha, at 8:02 the orange and black crimping tool has a "monster face."
Thanks!

[@TonyLiveTV]

Great video Mike. I like the crimp tool too.

[@MikesMercsandothercars]

Does the 560DSl use the same crimps or plugs? You know you'd be more than welcome to drop round and borrow the crimpers any time...By the way congrats on whooshing past the 1000 sub mark. Mike

[@TonyLiveTV]

@@MikesMercsandothercars I guarantee if I am anywhere near you I will be stopping by. The 560SL uses different connections. Also it has CIS injection and KE-Jetronics so there is a lot of differences. I will be uploading a video shortly showing every electrical connection on the engine of the 560SL. I’m getting closer to the first start. It’s taking me much longer than expected. I’ve had a few interruptions these past few weeks and I had to wait over a month to get a part from Mercedes.

[@michaelsliwinski8044]

thanks! fantastic informative video.

[@MikesMercsandothercars]

Thanks for your kind words....I knew someone out there would find it useful! Mike

[@ysteinholen3533]

Great video Mike. Very informative.
Do you know of any place where to buy wiring harnesses for the D-Jet (´74 450 SL)?
Or do I have to make one by myself....? My wiring is very crispy, and in need for a renewing, both wiring and contacts.

[@MikesMercsandothercars]

Thank you for your kind comments. Here are a few places you can buy a new harness....but they are not cheap:
kurth-classics-autoparts.de/gb/wiring-harness/288-d-jetronic-wiring-harness-m116-m117.html
www.kabelbomen.com/en/webshop/engine-ecu-cableharness-d-jetronic-mercedes-benz-350sl-450sl/
Where are you based?
Mike

[@ysteinholen3533]

@@MikesMercsandothercars Thanks for the links. I live in Norway.

[@MikesMercsandothercars]

I will soon be selling the wiring loom in my 450SL parts car. If you planned to make your own harness, it might work as a good template......rather than having to remove the harness from your car. Sometimes these projects take MUCH longer than expected! If you are interested, let me know, and I can ask my wife to take it with her when she goes on her ice swimming trip later in the year. Mike

[@ysteinholen3533]

Hi!
Yes, I might be interested in that. I have thought about making my own loom, so a template is perfect.
Where is your wife usually take her ice bath?
I live in Trondheim, in the middle of Norway.

[@sljgroup3229]

Mike where can I get the plastic plugs is it retail parts? Or does Repro parts have the plastic plugs and rubber boot.

[@MikesMercsandothercars]

These guys have everything you need from plugs to crimps:
www.djetparts.com/?lang=en
Mike

[@l.a.gindustries3105]

What crimper tool is that?

[@MikesMercsandothercars]

At time code 15.17 in the video I show you where I got the crimpers + the correct jaws for this job. The crimpers are Paladin and the jaws are no. 2033. Mike

[@motospotter365]

my boots even the actual fuel injectors have started to become brittle.

[@MikesMercsandothercars]

Thanks for your comment. The boots will eventually disintegrate - that is usual. The problem is that once they begin to lose their ability to shield heat, both the wires and the plastic on the injectors will become brittle. Two injectors cracked when I removed them from our 450SL parts car....and I was super careful. I guess most rubber bits will need to be replaced after 50 odd years. Mike

[@AndrewKidd14145]

Everything plastic after like 50 years is garbage.

[@MikesMercsandothercars]

Yep.