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W203 ... WDB 203742 ... C200 Kompressor Coupe ... Fuel Flap Actuator

johnsco

MB Enthusiast
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Joined
Nov 22, 2008
Messages
2,726
Location
Leeds, West Yorkshire
Car
E280CDI SPORTS ESTATE and C200 KOMPRESSOR SE Coupe Auto (1.8 lit petrol)
It's time to fix this item which has never worked since I bought the car.
I've tried spraying it a couple of times with WD40.
It doesn't look like this is going to work.
Searching thru the info on the web, it looks like this is the part - accessed from inside the boot lining on the right-hand side.
A 203 820 19 97
Can anyone confirm please.
 
Thanks alecmascot.
That's a very valuable resource in your link.
It has answered my question and confirmed the part number.
For years, I've used the Russian site for parts and diagrams.
It's difficult to navigate and often does not work.
But - This is much better.
Many Thanks.
 
The WD40 didn't work.
I confirmed the MB part number in the MB parts catalogue and then I ordered one from Global Parts.
There appear to be variants, so I ordered one with the guide that appeared the same as in the opening next to the fuel cap.
It came yesterday - So I gave it a try this morning.
The new item is as in the photos attached.
DSC05119.jpgDSC05121.jpg

The end of the guide can be removed by twisting and pulling the end, which looks the same as on my car.

By opening the small hatch in the right-hand boot side-wall, I could put my hand in and feel the item.
The steel operating rod does not appear to be enclosed in the black plastic guide tube.
I was rather hoping to remove the guide tube end and then remove the mechanism towards the rear of the car.
The problem is I can feel it and I can feel where the electrical connector connects into the plug on the body, but there is very little space.
There is no space to remove the electrical connector.
It is not clear how the mechanism is removed from the car.
The power lead is a two wire lead to the two-pin plug.
I tried the unit that I had bought, and found that the unit works (lock and unlock) by reversing the polarity of the 12 volt supply on the two wires.
There is no earth return to the circuit.
There must be a small dc motor in the actuator which works in one or other rotions..

By feeling round the unit in the car, I found a little manual rotator.
When I rotated it, the operating rod wound out to lock the flap.
When I pressed the key button to open the car, the rod retracted sharply to its unlock position.
Pressing the lock-button on the key had no effect.
Several times, I locked the car by winding the little rotator, and then retracted the rod using the unlock-button.

So - This says to me that the polarity in the two wires is not reversing and this is what is stopping me from locking the flap.
However - The wires are not broken and are both attached.
Otherwise there would not be a complete circuit.

My next move will be to break into the control wires and put a meter on them to check whether there is a reversing 12 volt supply.

I need advice:
1. How do I remove the actuator ?
I was reluctant to remove the boot liner without seeking advice.
It looks a lot of work and it may take me no further forward.
The actuator may be ok.
When I break into the wiring, I can apply a 12 volt supply in both polarities.
That will confirm whether the actuator is kaput or not.

2. Is there a module to supply this actuator ?
It must be separate from the door and boot locks, as they all work on both the lock and the unlock command.

I would be grateful for any experience and advice.
Thanks.
J.
 
After a bit more investigation, I've solved this little problem.
There is clearly no fault with the fuel flap actuator itself.
Reversing the 12 volt supply on the two wires that go to the reverses its direction ... lock ... unlock.
These are the two wires that go to the actuator:
 

Attachments

  • View into Right-Side of Boot.jpg
    View into Right-Side of Boot.jpg
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I traced the wires to the fuse box on the left side of the boot.
Inside is a panel.
The two yellow relays towards the bottom of the panel are the polarity-reversing relays.
Fuse 15 is the fuse that controls their operation.

Inside of Fuse Box - 2 Yellow Relays are Polarity-Reversing Relays.JPGFuse and Relay Box on Left-Side of Boot.JPG
 
The yellow relays G and H are the polarity reversing relays:

Mercedes-Benz-C-Class-W203-2000-2007-fuse-diagram-luggage compartment.jpg
 
I removed the two yellow relays and checked them out with my multimeter.
The coil of one of them was open circuit.
It looked like it has suffered water damage and was beyond repair.
MB Part No. A002 542 12 19Relay - A002 542 12 19.JPG
 
I ordered a replacement Heller relay from one of the after-market suppliers.
About £2.20 + delivery.
The Hella number is different and it is black, but there are a number of these relays that are functionally the same.
Plugged it in .... Result ! .... The fuel flap lock actuator now works correctly.


Scan_20220202.png
 

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