HOW TO repair faulty turn signal using Mercedes repair kit

[Tim_Q]

HOW TO repair faulty turn signal using Mercedes repair kit
I couldn't find any advice on how to do this so here's a DIY guide.

This is a common problem on the C class W203 and maybe other models. Basically the headlight unit is poorly made and the contacts to the turn signal bulb holder burn away.
Mercedes dealers can supply a repair kit for this problem.... the part no is 203 826 01 82 and it costs £20 inc VAT.

It took me a little while to work out where to connect it. There is a single connector to the headlamp unit. Pull this off, that's the easy bit. The difficult bit is removing the turn signal terminal pin from the connector. It's the thin black/white wire (at least it is black/white on the passenger N/S unit I worked on. You need a very small screwdriver/pointy thing to shove down the top and bottom edge of the terminal pin..

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Keep doing this and gently tugging on the wire and eventually it'll slide out (hopefully undamaged). You will then see the prongs that you have pushed in to allow it to come out. Lever these back out again so it will lock into your new connector in the repair kit, there are 2 holes but one should have a blank in it already. It should now look like this...

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That's the hard bit done, now it's just the earth lead to connect. On each side of the engine compartment there is an earthing point on top of the wheel arch. Undo the nut with a 10mm spanner, pop the earth lead onto the terminal and tighten it back up again...

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Now pop your bulb in the holder...

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Screw it back into the headlamp unit then if you have a wiretie lying around tidy it all up by tying the new connector to the wiring harness...

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Don't forget to plug the main connector back in and test ALL your lights.
Job done! Hope this helps. If anyone wants to add further to this thread please feel free.

 

[Tim_Q]

I've just done the drivers side too! Just as an update.... the wire you're looking for here is green/white. I also had to remove a cylindrical shaped 'thing' connected to the vacuum system to gain better access to the headlamp electrical connector. No idea what it is but there are 2 10mm nuts securing it and it's much easier to work on if you remove this and pull it out of the way.

 

[richard]

Excellent write up !

A slightly easier way to remove that cable is to open up a paper clip and then fold it over so you have 2 equal length "ends". Then you can shove that down each side of the connector in the two slots.

The correct tool can be seen here:-

Comand Online Ltd :: Tools :: Contact Removing Tool

But paperclip is good unless you want to do this regularly or the connector has got damaged.

Richard

 

[divydovy]

Thanks, more info

Hey Tim_Q,

Thanks for your excellent guide. I carried out this repair to my 02 C240 this weekend. There are a couple of bits of info I found that might help.

I was replacing the FR turn signal. For me, the wire I needed was black/green. Comparing to the FL, it looks like the wire required is the one next to the thick brown (earth?) wire.

Also, there is an easier way to get the terminal pin out (at least there was for me). The white inner plastic shield on the connector can easily be removed. From there, you can push the holding prongs from the side of the connector using a small screwdriver, rather from above. You can see the slots to do this in the second photo - a series of little block shaped holes across the front of the connector. Anyway, worked for me.

Cheers again,

divydovy

 

[Alfauno]

connector disassembly

Hey Divydovy,
I know it's been over a year since you posted your comment on the turn signal retrofit, but can you share how you removed the white plastic cover in the headlamp connector plug? I've pried on it, but can't get it to move. Thanks!

 

[Rock]

hi all, ive got this same problem with my C-class 51 reg, front right, connectors are totally burnt out!

the write up above looks and sounds very confusing although i know might not be.

can anyone direct me to someone who might change this for me? i reside in essex.

thanks inadvance

 

[Alfauno]

I did mine today - very simple, actually. I did take the shortcut and cut off the plug provided in the retrofit kit and just spliced the wires.
The wires to cut are the striped ones, right next to the brown wire on either headlight plug. You cut off the plug on the retrofit kit, and splice that to the striped wire you just severed at the headlight plug. Screw down the provided ground eyelet, and put the new socket in the headlight housing (with a new bulb), and you're good to go. I used an insulated connector, with a good crimping tool, to make each splice, and filled the crimped end with silicone sealant to keep moisture out.

 

[QuixX]

I did my left today. No more pictures in this thread.

I had to solder. There is a ground-screw near the middle of the frontwing. The other wire was cut and soldered to the "pin 1"-wire of the headlamp-unit's connector plug.

(I hope, my text isn't too bad)

 

[mr. shr]

My Mum's W211 is doing the same.
I replaced the bulb holder only to THEN find that there's a modified part that needs to be bought.
Question is, what does the modified part include? Is it simply a new lamp holder with wires soldered onto the terminals? If so, it it worth buying the modified part or can I just solder wires onto the new lamp holder I've already bought.

Anyone got a pic of the modified part by any chance?

 

[Jargonaise]

The picture links are broken any way that I can view them?