1996 C220 Engine Wiring Harness - Mercedes-Benz Forum
 
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post #1 of 10 (permalink) Old 12-24-2007, 06:44 PM Thread Starter
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1996 C220 Engine Wiring Harness

It appears that my engine wiring harness is starting to age and malfunction. This is causing repeat check engine lights to occur, but my car still runs ok. The dealer wants $1080.00 for the part (Part #:A 202 440 96 05), and I was curious if this can be purchased anywhere else for cheaper. Has anyone found a place other than the dealership that sells this?
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post #2 of 10 (permalink) Old 12-24-2007, 07:17 PM
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Those ones look like a serious problem

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Originally Posted by rameen00 View Post
It appears that my engine wiring harness is starting to age and malfunction. This is causing repeat check engine lights to occur, but my car still runs ok. The dealer wants $1080.00 for the part (Part #:A 202 440 96 05), and I was curious if this can be purchased anywhere else for cheaper. Has anyone found a place other than the dealership that sells this?
Did some research on that, there was one on e-bay but it was for a 95 model not a 96'. I would keep checking the ebay site for one popping up.
Here is a link to some history of several years of problems with that particular models wiring harness issues that you most likely know about.

Mercedes-Benz 1991-1996 Engine Wiring Harness Defect NHTSA Complaints Summary

Those harnesses do not look like they are even worth trying to fix after reading above article. I would hate to even ask what the labor charge at the dealership would be to install a new harness. B
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post #3 of 10 (permalink) Old 12-25-2007, 02:59 AM
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I replaced my C36 (M104 engine) engine harness by myself. It is quite straightforward and took about 3 hours. Having said that, some parts were a bit fiddley for access (eg. anti-knock sensor and starter motor). I would think MB or a Merc experienced auto-electrician should charge no more than 1.5 to 2 hours labour.

This link is very helpful:
MercedesShopWiki: W124 Engine Wiring Harness Replacement

Last edited by OzC36; 12-25-2007 at 03:10 AM. Reason: Add link
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post #4 of 10 (permalink) Old 12-28-2007, 03:50 PM
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BTW guys... I rebuild these harnesses myself, all soldered and shrink wrapped, using fuel and heat resistant AUTOMOTIVE wiring, along with loom and tape. I just got done with another c280 harness, so I am open as of now... I charge 300.00 + shipping, + any new "pin bushings" (electrical connestors) that i have to order from mercedes. . the Last c220 harness was a total of about 336.00 after all was said and done.

1995 C220 (W202)
Brilliant silver metallic


Viper Remote Start, Keyless and Security system
JVC KDAVX77 with DVD, BLUETOOTH and IPOD
Clarion component speakers
2 MTX 10" subwoofers - Vented
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post #5 of 10 (permalink) Old 12-28-2007, 09:47 PM
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Originally Posted by doin12volt View Post
BTW guys... I rebuild these harnesses myself, all soldered and shrink wrapped, using fuel and heat resistant AUTOMOTIVE wiring, along with loom and tape. I just got done with another c280 harness, so I am open as of now... I charge 300.00 + shipping, + any new "pin bushings" (electrical connestors) that i have to order from mercedes. . the Last c220 harness was a total of about 336.00 after all was said and done.
Pretty cool. Do you require the harness to be sent to you leaving the car down or do you have spares that can be used and a core charge to send our old ones back to you?

I would have a hard time having my car down that long. As you can guess, I know I have an issue but it isn't REALLY bad ie the car still runs fine.
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post #6 of 10 (permalink) Old 07-02-2008, 02:12 PM
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As of now, I need the harness from your car to rebuild.... HOWEVER.. If anyone goes and has a NEW harness put in, they could send me their old one as a "donation" - this would allow me to ba able to do an exchange, and limit down time! --Just a thought...

Also, as with EVERYTHING it seems, the cost of supplies is going up, nothing insane, but here is where i am sitting right now:

(All prices are not including parts such as pin bushings, ETC)

c220 harness - 380.00
c230 harness - 420.00
c280 harness - 460.00
c36 harness - 480.00

Other harnesses such as E-class harnesses are estimated to be in the range of 350-500.00 for full rebuilds. Price also varies , depending on how badly degraded your harness already is! I have had 2 harnesses so far that were nothing but dust and copper once i unwrapped the tape!


Keep in mind also... I am not just wrapping your wires in tape, I am REPLACING EVERY WIRE! I also use solder and heat shrink tubing on all connections, and replace any broken plugs.

My harnesses are then sealed and wrapped with 3M 33+ tape.

For an extra 30.00 I will do a bit of "overkill" -- After the first time the harness is taped, I will cover the harness with wire loom, and tape it again, making it even more protected, not to mention better to look at!



EDIT - THIS POST IS OVER A YEAR OLD. PRICING HAS INCREASED DUE TO INCREASES IN PRICES OF SUPPLIES AND SHIPPING.

1995 C220 (W202)
Brilliant silver metallic


Viper Remote Start, Keyless and Security system
JVC KDAVX77 with DVD, BLUETOOTH and IPOD
Clarion component speakers
2 MTX 10" subwoofers - Vented
Total 500.1 subwoofer amplifier
17" MB wheels - 2002 E class / Chrome Star centercaps
Clear corner markers
35% Tint all around
LED 3rd brakelight

Last edited by doin12volt; 09-12-2009 at 06:26 PM.
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post #7 of 10 (permalink) Old 07-15-2008, 04:49 AM
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Hi doin12volt,

My repaired harness arrived a few days ago, many thanks!

It looks far better than new and certainly more robust to withstand the engine bay temperatures. A very professional job indeed. Now I just need a spare few hours to install it...can't wait!
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post #8 of 10 (permalink) Old 12-07-2009, 06:35 AM
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I have a question. If I send my harness out, how would you suggest I ensure that the I know where to plug/connect them back after I get the repaired harness? thanks

the sooner you start, the sooner you'll get done.....
96 C220 330k
85 300D (sold)
84 300D (sold)
80 300TD (sold)

Last edited by tobybul; 12-07-2009 at 10:12 AM.
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post #9 of 10 (permalink) Old 09-01-2011, 08:26 AM
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C220 1996

Are you still doing wiring harnesses. What would it cost to do a 1996 C220? And where are you located? Thanks.

the sooner you start, the sooner you'll get done.....
96 C220 330k
85 300D (sold)
84 300D (sold)
80 300TD (sold)
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post #10 of 10 (permalink) Old 12-30-2014, 02:41 AM
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I don't know I should consider myself very lucky or unlucky. My car is 96 C220. Over 200,000 miles now! I noticed that the wires looked bad may be since a couple of years back. But I seldom open the hood and trying to use extended oil and filter to change every 10,000. The car never gave me much problems. The vacuum leaks but I just need to shut off the central vent and use the others. But after the last smog check the engine check light is on. If I have time I would have looked into it more, or if I have the budget I would have taken it into a mechanic's shop and fix it. There's is always the possiblity of having to junk it because it's worth about $1000 depending on where you look.

Now it's running on check engine light for about 2 years now.

The side story is that I replaced the engine. Because when the engine broke, there's no way not to fix it or not to junk it. It doesn't make a lot of sense but it's a long story (posted) if you are interested. I asked my mechanic to guarantee that I can pass smog after engine replacement but he couldn't. That's understandable.

After the engine replaced, my mechanic replaced a few things such as MAF and spark plug. That's long overdue because I don't want to junk the car with a couple of new parts in it. The engine check light is still on. Then the bomb came. He suggest that I have to replace the engine harness. The engine and power train is running "fine" he said, the problem is electrical.

The MBZ engine wire harness is now some $1000 to $1200. Rebuild ones are a couple of hundred if you can find one.

Many years ago I added a CD player in the trunk. Silly me. I thought it would be like making an extra electrical outlet but now I know it's a bad idea. Circuit city techs took a long time and I think they have to drill holes and unbundle the harness wires. I blame them for moving the harness in the trunk. It wasn't secured and got close to the trunk hinge. There was a short but a short electrical tape did fix it. I think it just affected the lights at the back.

Since the engine change, it seems that the harness went downhill. Now my engine has a lot of black electrical tapes around it. Again long story. I seems to have all the symptoms of soy bean harness without realizing it and thought the engine was the problem. The car might stall when accelerate from low speed but not total loss of power. The car may not run smooth after a few miles and shakes badly when idle. A simple turning off the engine will cure everything and nothing may happen for the rest of the day. It will start fine the next but something will happen once a day to a couple of times. The other way is to hard accelerate from almost stalling. It will run normally after picking up speed or a little shakey but not bad at normal speed. So it could be MAF wire shorting and cylinder misfire. BTW the cruise control stopped working long ago. The ABS light comes one once in a blue moon for a while but the anti-long brakes seem to work still. The "bulb light" comes on when I turn on the headlight when all the lights are working as far as I know. My windshield washer tank empty indicater is on but it has plenty of water in it. Other than these, I still dash across freeways everyday on the fast lane. Now that I read about soy bean harness, I am not so sure ...

What are my options? I am still recovering from the engine change this summer, financially. (and from the trauma) I also suffered a total blow out and brought 4 new tires. The ride became very rough at high speed. The tread depth were barely legal to illegal. They were telling me to replace them for a long time but I thought it was the engine.

If I buy new or rebuild harness, can I put on it myself? Are the plugs reasonably accessible without taking off major components? I'm still in good terms with my mechanic. He offers to put it on if I get something from eBay. But still he didn't give me quotes. I didn't push because I can't afford any harness at the time. What is the "going rate" for labor, how may hours? Here the starting is $90/hr.

If I were to put on the harness, I may just as well consider repair / rebuild myself. For soldering the nightmare for me is surface mount electronic components and copper pipes in the dry wall. Can harness be worse? I read that you can get connector pins from MBZ? In that case there could be no show stopper. You can repair or replace inidividual connectors. Are the documents / part numbers easy to find? (Finally after years, I manage to buy the exact vacuum connector plug that I broke. But I still haven't find good enough you-tube video to join vacuum lines.)

I can also re-insulate / repair the wires in situ, if only for a temporary fix to pass smog. Can someone comment on these?
Color coded electrical tapes are mostly rated to 80 deg C. Are they used on autos? I would think they need some outer wrap with higher temperature resistence.
Liquid electrical tape seems pretty good. I think it's rated over 125 deg C. It takes 4 hr per coat but I have time. Any other catches?
I have tried magic tapes for plumbing and they are awesome. They are rated at higher temperature with excellent insulation properties and of course they seal out moisture. I can use it when liquid electrical tape is insufficient, instead of shrink wrap, and for cable tie.

As for whether to junk the car still, the current situation is that 3 out of 4 shocks need replacement. The engine consumes quite a lot of oil even with the addictive my "master mechanic" suggested.
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