Starter issue
Thread Starter
Junior Member
Joined: Mar 2017
Posts: 21
Likes: 1
From: Las Vegas
02 Mercedes G500, 71 BMW 3.0csi, 56 VW Beetle
Starter issue
My 2002 G500 lately has strange issue with starter blowing the fuse constantly. Went on a light offroading with mostly dirt trails, then went to start later in the day and nothing. No crank, just blown fuse.
Swapped out the fuse for starter under the passenger side dash area, fuse #52. Started right up fine.
Next day went to start and nothing again, fuse #52 blown again. Changed and right away when I try to crank, fuse blows. Did this couple times with new fuse replacement. So I decided maybe bad starter, so I went and got a remanufactured started from Autozone. Swapped it out yesterday and car started right and I did it couple times just to make sure. Then after the 4 or 5 start, same thing fuse blows and no start again.
So I thought maybe it's the relay that's gone bad, so I went to dealer and got 2 oem relays. I found diagram online of fuse box under dash and shows G which I think is the relay for the starter. The stock paper diagram in driverside dash for fuses says G but the G it refers to a fuse on driverside. The fuse box on driverside dash has G but that fuse is fine. I went and swapped out the 2 relays on the passengerside with G and K which are adjacent to the starter fuse #52. Went to test and hear a small click and nothing. Checked the fuse and it's the #52 starter fuse blown again.
I'm kinda running out of ideas right now. Anyone have anymore ideas I can try? Please help! Thank you!
Swapped out the fuse for starter under the passenger side dash area, fuse #52. Started right up fine.
Next day went to start and nothing again, fuse #52 blown again. Changed and right away when I try to crank, fuse blows. Did this couple times with new fuse replacement. So I decided maybe bad starter, so I went and got a remanufactured started from Autozone. Swapped it out yesterday and car started right and I did it couple times just to make sure. Then after the 4 or 5 start, same thing fuse blows and no start again.
So I thought maybe it's the relay that's gone bad, so I went to dealer and got 2 oem relays. I found diagram online of fuse box under dash and shows G which I think is the relay for the starter. The stock paper diagram in driverside dash for fuses says G but the G it refers to a fuse on driverside. The fuse box on driverside dash has G but that fuse is fine. I went and swapped out the 2 relays on the passengerside with G and K which are adjacent to the starter fuse #52. Went to test and hear a small click and nothing. Checked the fuse and it's the #52 starter fuse blown again.
I'm kinda running out of ideas right now. Anyone have anymore ideas I can try? Please help! Thank you!
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Joined: Nov 2002
Posts: 1,028
Likes: 133
From: Massachusetts
2018 GLE350, 2014 G550, 2000 SL500, 1980 TR8, 1995 E320 Cabriolet
I would look for a some chafed insulation some where in the starter solenoid lead. Crawl under there and follow it back as far as you can. The frequent, but intermittent blowing of the fuse really sounds like something in the solenoid circuit is occasionally shorting to ground.
Thread Starter
Junior Member
Joined: Mar 2017
Posts: 21
Likes: 1
From: Las Vegas
02 Mercedes G500, 71 BMW 3.0csi, 56 VW Beetle
I would look for a some chafed insulation some where in the starter solenoid lead. Crawl under there and follow it back as far as you can. The frequent, but intermittent blowing of the fuse really sounds like something in the solenoid circuit is occasionally shorting to ground.
Thread Starter
Junior Member
Joined: Mar 2017
Posts: 21
Likes: 1
From: Las Vegas
02 Mercedes G500, 71 BMW 3.0csi, 56 VW Beetle
I would look for a some chafed insulation some where in the starter solenoid lead. Crawl under there and follow it back as far as you can. The frequent, but intermittent blowing of the fuse really sounds like something in the solenoid circuit is occasionally shorting to ground.
I ask my mechanic friend who works at local MB dealer and he said it sounds most likely i have a bad front SAM control unit. Anyone know how i would test the SAM unit?
Here's some pics of the lead from starter to engine.
Insulation on wires from starter are breaking apart.
Wires from starter with flexible sleeve removed
New flexible sleeve installed over wire leads from starter solenoid
