Preventing my van going up in flames

May 2, 2017

It has been raining a lot for the last weeks in Berlin. I was eager to install the solar panels. So I drove around to find a bridge that offers a dry place to work on the roof. While driving in the rain I realized that the wipers moved very slowly.

I couldn’t find any issues with the wipers or the motor. However, I also observed that the blinkers were flashing a bit weak. While diving deeper into the issue I realized that several electric devices operated weakly:

  • the headlights
  • the blinkers
  • the wipers
  • the fan for the heating
  • several lamps on the instrument panel

Hmm, where should I start looking for the root of all these problems? :thinking: With the help of the wire diagram I tracked the issue down to the fuse box.

Wire diagram for a Mercedes-Benz 207D/209D

All fuses seemed intact however some connectors looked really bad:

Fuse box in bad condition

Some cables even looked scorched:

Fuse box in bad condition

On some of these connectors I measured a resistance above 200 Ω. :scream: The connectors were held together by bolts that got loose over time. These loose connections caused very bad conductivity, resulting in a lot of heat which further led to corrosion. A vicious circle!

Ignoring this issue might have resulted in my van going up in flames. :fire:

All shops I checked were out of stock (part number A0015450001) so I sanded all the connectors,

Sanding the connectors

replaced the loose bolts with proper screws and linked the connectors with a thick copper sheet.

Screws replacing the loose bolts

Before installing the fuse box back into the van I measured the resistance of every single fuse connection:

Repaired fuse box

All connections below 1 Ω. Yay, another fixed issue! :heavy_check_mark:

Installing the solar panels will hopefully the next project! :pray: