Doing a bit of mid-level maintenance on my 03 Disco. My valve cover gaskets are very brittle and leaking, they are 7 years old so I decided to R&R the covers and install new gaskets and bolts.

I was also in the process of changing out the power steering pump, I think the bearing was going out so I already had the AC compressor, the fan, the pump, the upper shroud removed. I watched the Atlantic British videos on doing both the PS pump as well as the valve cover gaskets. Getting those few bolts loose behind the intake manifold where the secondary air pipes and the upper mount for the coil is really a challenge for my fat old fingers.

I finally removed the intake manifold and also disconnected the 4 spark plug wires to make more room to remove the cover. I then got the right cover removed and the old gasket and all 4 barrel washers and installed a new gasket and put the cover back in place.

I moved to the other side of the engine and it certainly is a lot tighter what with the wiring harness and the heater tubes and hoses. When I went to remove the spark plug wires I found the middle 2 brittle and one fell apart in my hand! The front one and rear cylinder one are fine. I am attaching a picture.

Needless to say I now need to order a new set of wires but has anyone seen anything like this? I put the wires on in 1009 or 2010 and they have about 30,000 miles on them. The engine seemed to be running fine before I started so I assume the wires were getting the spark to the plugs.

Thanks in advance.

 

If they're from the year 1009 then I'd say you got a really good lifespan out of them!!!!

I'd recommend some spark plug boot heat covers on your next set. They slide over the boot and provide protection between the hot exhaust manifold and the rubber spark plug boot.

Kingsborne sells them for around 30.00 for a set of 8.

 

Sorry, that was 2009 but it may have been 2010.

I called the tech guys at Magnecor and they said it sounded like heat damage but the boots were installed in a normal way and not any closer to the exhaust manifold. They offered for me to send in the damaged wires and they would check them and replace the boots if necessary. I ended up just ordering a set of the Kingsborne 8mm from their website. The price was good and I figure I will give them a try. Much easier to install them since I have the intake off.

 

Woah, are those $30 Kingsbourns 8 mil? I thought I was getting a good deal at $80 for my STI set compared to the $120 Magnecors.

To answer OP'S question, that's very strange and not something I've seen, but after hearing that I might just be investing in some wire insulators myself.

 

Wow I have had my Magnecores since 2008 and they have been great. I think if you order a set they should warranty the old set straight up.

 

no reports of bad kingsborns yet

 

I've seen it happen on every D2 I've ever owned in TX. The OEM Bosch wires would really do it! It also seemed worse on the middle wires on the D2's with SAI.

I highly recommend those heat protector boots on any D2 if you want to get the most life out of your spark plug wires.

I've heard nothing but good things about Kingsborne wires/products. I will be ordering a set for my Kalahari when the time comes.

 

Sorry if I wasn't clear but the worn out wires were Magnecore. They were installed in 2010 0r 2011. I went ahead and ordered Kingsborne this time based on some of the reviews here and the price and availability. I called the Magnecore tech guy and he said it sounded like heat damage but they are the 2 center plugs on the passenger side. Not sure why they would be in a hotter area than the other.

 

looks like heat damage to me too CH....don't know why...maybe you had a manifold leak near those boots? how were your others compared to those two?
I had the red magnecore wires on a D2 from 2007 or 2008 till 2014 and they still looked like new..or close....no cracking or dry brittle areas like yours....the boots were still soft and in good shape...the only problem I had the entire time was I pulled the wires off to change the plugs once and when I pulled the wire off of one plug (by the boot) the metal terminal stayed on the plug...I contacted magnecore with the measurement and they sent me a new wire for like $10...if I remember right..it wasn't much..
I changed them out in 2014 only because I was doing head gaskets, timing chain and gears, oil pump and a lot of new stuff...resealing the engine, etc...so just decided since they had near 100k on them I would put new wires on too...and I bought the same wires again...since they worked for me...If I bought new wires today I would probably go with the kingsbornes..since everyone is giving them good reviews....but just wanted to pass along I have been happy with magnecores...on mine