V12 Fire Warning!

    Hey Guys,


    I have a serious warning for all V12 owners that was discovered today. Whilst fitting my alternator back on to the car following the overrunning pulley mod, I found that the main cable running from the alternator to the jump start post housing was severely damaged from what appears to be ageing.


    My car has 40,000m on it and has had a pampered garage life so I think you should all check this cable. What is worse is the cable runs through a metal tube bolted to the engine and IS NOT FUSED!!! A direct contact between the cable and its metal sleeve would directly ground out the both batteries.


    Consequencies are obvious and what is even more concerning is that even with my contacts at BMW the replacement part is now DISCONTINUED.


    What I have done as you can see from the pictures is replace the (approx) 8-Gauge original cable with some new 2-Gauge and fitted new Gold Plated ring terminals. The larger gauge cable should reduce the running temperature of the cable and it is sheathed in a silicon cover. It is also far more flexible than the original cable and the Gold terminals will give better electrical contact.


    Enjoy the pics then go check your car!


    8Tech.

    Hi 8Tech, I don't know if you already knew this but this cause of fire was already noticed over on RF where one owner had a fire. The cause was later identified as being most probably due to this wire so I can only second your warning - get that cable checked!



    Hi 8Tech,

    where can you buy this new 2-Gauge cable and how much does it cost?

    Thanks for the heads-up. There's always something to do with these cars. There is a lot of heat under the bonnet and I also found that most of the sleaving material on the wiring harnesses has gone very hard and stiff. I was looking at that metal pipe the other day, wondering what it was for. I'll have to take a better look at it and replace the cable, along with all the fuel hoses, vacuum hoses and other stuff. Fortunately, in my line of work, I have access to high-temperature cables and crimping tools.

    Zitat von Christoph;61148

    Hi 8Tech,

    where can you buy this new 2-Gauge cable and how much does it cost?


    It is approx £10/m and you need 0.7m plus a couple of 2 Gauge ring terminals at about £5 each. so £20 all in and that is a good investment. Many car stereo shops should have this but if not I can send you some for these prices. Just add post.


    8Tech.

    Gerry,


    What year is your car? I checked my cable (Sept 94) this evening and although the insulation is hardened it is still intact. I also noticed that it has a secondary plastic sleeve around it. There is no silver sticker on it though so it may have been replaced in the past?


    Nevertheless, I will change it for silicone or similar.

    Zitat von arnie;61195

    Gerry,


    What year is your car? I checked my cable (Sept 94) this evening and although the insulation is hardened it is still intact. I also noticed that it has a secondary plastic sleeve around it. There is no silver sticker on it though so it may have been replaced in the past?


    Nevertheless, I will change it for silicone or similar.


    Mine is one of the last......a 1996 CSi.

    fire warning


    Like Arnie, I checked PDQ. Both ends of the cable where it exits the metal tube look fine on mine thank goodness. Visual check and finger tip check shows all good.
    I am posting this only because like Arnie, I have appear to have a secondary sleeve. Where the cable exits the metal tube at the battery jump/charger post end, there is a second sleeve visible around the actual cable insulation.
    I just mention this to add to the mix.


    Mine is a '93 Ci with 95k miles so it is probably not age/mileage dependent.

    If the batteries are not in good shape then the electrical loading on this cable will increase and its temperature also. This could lead to faster degredation. As, I mentioned, I will probably change it anyway.


    I can't remember the exact dates dates, but MB cars manufactured some time in the 1990's suffered from similar cable degradation as an attempt was made to use bio-degradable materials, which ended up decaying long before intended.:oops:

    I have another idea on how to add some safety to this design which could help prevent a fire in the event of a short and could be a quick fix for those not changing the cable.


    Car Audio specialists have a fuse and holder arrangement that uses very high current blade fuses, available in 150A certainly. It should be possible to disconnect this lead from the jump terminal end and bolt it straight to the fuse holder, then use a small jumper cable from the fuse holder to the jumper terminal. A cable failure would then blow the fuse, isolating the cable and the only further damage would be a damaged alternator, not a small issue but better than a fire.


    http://www.vehicle-wiring-prod…estore/fuses/holders2.php


    http://www.vehicle-wiring-prod…tore/fuses/fuses.php#mega


    8Tech.

    Full alternator cable repair kits will be available by next week and will include the correct length of 2-Gauge silicon sheathed cable, (probably in blue tint), 2 new Gold 8mm ring terminals, heat shrink and the correct length of professional motorsport cable thermal protection sleeve. Cost of the stock kit will be £45 inc VAT and UK postage.


    The 2nd (NASA) kit, which includes the thermal jacket for the metal tube is an additional £45 inc VAT and UK postage.


    I have ordered materials to assemble 10 kits and 4 are pre-sold so if anyone would like one, please let me know.


    Thanks, 8Tech.


    Pics to follow when the components have arrived.

    Here are the V12 alternator wiring kits now ready for despatch to Wuffer for distribution in N America. The kits are available in blue only at the moment and each kit comes with the correct length of 2-Gauge cable, multi core and silicon sheathed, and the thermal protection is professional motorsport heat reflective insulation because the heat generated is radiant heat and requires a reflective surface for protection.


    The kits also come with gold 2-Gauge 8mm end terminals and two small lengths of heatshrink. The kit also includes an 8mm stainless steel washer and a motorsport spec stainless serrated flange nut to allow connection of the cable to FAA/Milspec recommendations to the alternator. Most competant home mechanics will be able to carry out the repair with the fully illustrated instructions included with each kit.


    The kit including the optional thermal blanket is also shown. (really only required by turbocharged car owners)


    My kit is the most expensive you can buy, but quality is seldom cheap and a burnt out V12 is definately even more expensive. Once forum members have finished purchasing the kits I think I will start listing them on eBay, there doesn't seem much competition on there.


    I will be sending out the kits already ordered this week with the kits for N America being available from Wuffer in the next couple of weeks.


    Cheers Guys,


    8Tech.

    Gerry, these look fantastic!


    Just a small point, which is not intended as any criticism:


    You should perhaps point out to buyers to ensure that they have or can borrow a suitable crimping-tool for the lugs, since poor crimping gives high contact-resitance, leading to high local temepratures and possible melt-down of the plastic-cased terminal blocks. (Hammers, pliers or vices, would not be classified as suitable tools for this size of terminal lug.)

    Gerry, Checked mine this weekend and found it to be ok no sign of heat damage wear of cracking, it has an extra cover on the wire so may be this helps? but I know where to get one if I need it. :winkwink:

    1991 850ci,
    2001 540
    2002 4.6 Range Rover Vogue

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