BenZ190D

This is a 04 C230 Kompressor with 6-speed manual, with 152,000 miles.

I drove home during a heavy rain today, no problem on the road. But on my way to the gym, I stopped the engine during a known long wait at a particular traffic light. The car won't start again. Jumping didn't help. Finally I got it towed back home.

Checking the battery, it's fully charged. I then let my wife turn the ignition switch on. From the engine compartment, I heard a clear click, followed by a low whining sound when the key is turned to start position.

What should I look next? The fuses looks fine. But I don't know which relay is responsible for starter. such is also not reflected in the in the fuse chart.

thanks much for sharing any insight.

Ben

RWDlifer

Your starter is going out....or it's already toast. Get a long handle breaker bar or something similar and tap the starter as someone cranks it...don't short anything or fry yourself lol

BenZ190D

thanks much for the insight. I'll try hammering on it today. I read that the starter motor can be renewed by just replacing the worn-out carbon brush. Years ago I did that on my old 87-190D alternator when it worn out, for just $2 by replacing the carbon brush in the voltage regulator. But it seems the Kompressor is magnitude more difficult to repair than the old 190D.


Can anyone please share some experience over the do-ability of the job of replacing the starter motor?

RWDlifer

It's not difficult at all. From underneath you'll need to detach the bracket holding the AC lines to the trans bell housing then disconnect the steering linkage where it goes into the rack. Then it's just disconnect the wires going to the starter and remove a couple of bolts. Took me less than 30 min to remove...

BenZ190D

thanks so much RWDlifer. that's very encouraging knowledge. I tried today to locate the starter motor, but couldn't find it. When I face the vehicle, on the right side bottom there is a device looks like the one in the manual. But the manual says it's lower at the right side, typically it's relative to the seated driver. so I'm a little confused, and didn't want to hammer the wrong thing. Will open the bottom panel tomorrow, and report back.

Ben

RWDlifer

Lower driver side....under the supercharger. I'm assuming you have an M271

BenZ190D

Yes, I have M271. I managed to remove the steering column end of the steering coupler, but unable to separate it from the steering gear input shaft, it is snug tight. is a special tool needed? I found nothing to pry against and don't want to damage the plastic cap.

C230 Sport Coup

Remove the bolt connecting the 2 sides of the shaft.
Push up on shaft. It will drop down, I made a you tube video on this.

BenZ190D

thank you. I was able to separate this end by prying open the securing square clip, but not the rack-and-pinion end. I removed the bolt, but it is snug tight, and there is nothing to pry against.

BenZ190D

thanks to your video, I avoided removing the lower end of the steering coupler, could wiggle out the starter. Still I must curse the guy who designed such a painful configuration. he should do a few of starter replacement jobs to see himself how awful it is.


The carbon brush is complete gone, no wonder hammering on it didn't work. Will put in a new carbon brush kit tomorrow. Looks good for the weekend.


this is partially my own making as I had the habit of turning off the engine at traffic lights I know that take a long time to turn green. it turn out lowering CO2 emission didn't play well with my wallet and soring joint from lying hours under the car besieged by hundreds of mosquitos

BenZ190D

I'm rebuilding my starter motor with new carbon brush set. I see the gears inside the unit are dry and clean. I wonder if I should grease them before installing back.


I do worry grease might make them slip, as in my Craftsman drill, which slips easily after I dropped lubricant to the gears.


Any insight would be appreciated.

RWDlifer

A dab of grease here and there is prolly ok, but not lubing the whole dang thing

BenZ190D

2004 C230 Kompressor Sport with 152,000 miles.

Finally, I could reassemble the motor with new brushes. But to my surprise, when I apply briefly 12V from a battery. The shoot-out gear doesn't even move, nor do I see spark from the contact as it did before the rebuild.

Could my pre-rebuild test with jumper cable damaged the circuit? What can I do to isolate the problem?

thanks much!