How to replace blower fan brushes.

1993-Present: C200 CDI, C220 CDI, C270 CDI, C180, C200 Kompressor, C230 Kompressor, C220, C230, C280, C300 C350, CGI & CDI BlueEfficiency variants
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Ivanerrol
Mercedes Demigod
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Joined: Sat 12 May, 2007 3:21 pm
Model you own: w204
Location: Melbourne

How to replace blower fan brushes.

Post by Ivanerrol » Mon 06 May, 2013 10:47 pm

W202 Blower Fan Fix

Intermittent or non operation of the HVAC blower fan in the w202 or W210 series
Is often caused by worn out fan motor brushes.
These brushes can be sourced easily on the web – particularly on U.K. ebay sites for very little monetary outlay. I sourced a set from a U.K. supplier and including post to Australia the cost was just under AU$10.00

Another fault is often the blower fan regulator. These are also easily sourced on U.K. ebay sites. Don’t bother getting a second hand module. It’s just as likely to go faulty on you in short time.

The Blower motor removal and replacement is straight foreword – unlike the previous W124 or W126 models. The fan motor is located above the front passenger kick panel.

In the case of this particular ’96 W202 C200 the blower fan would not operate at any speed using the controller switch on the console. If 12 volts was applied directly to the motor the fan did operate – but very noisily.

First step is get access to the motor.

Passenger side foot well. Under dash kick panel needs to com out.
Before getting the panel out the air inlet cover must be removed
Here’s the cover
Image

Use a Philips head to turn the screw half a turn. Then the cover pulls out and off

Image

The under dash panel has three Philips head screws to be removed.
Image

The panel pulls forward and out
Image

Next to be removed is the electrical connection from the blower fan cover

Image
W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

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Ivanerrol
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Re: How to replace blower fan brushes.

Post by Ivanerrol » Mon 06 May, 2013 10:47 pm

The blower fan cover has two clips that hold the front on tight – slide these towards the centre on both sides
Image

Pull the cover downwards and forwards to get it off.

Get upside down in the foot well and look up you will see this
This is the blower fan motor and arrowed is the speed regulator.

Image


All screws holding the fan motor and regulator in are Torx20 heads. You will need to buy a set of Torx bits and Torx sockets to work on W202 and W210 M.B.’s onwards.

Image

Here’s an image of the fan motor in situ with the regulator removed. The regulator must be removed to enable you to get at all the screws holding the motor in place. Note that there are 4 screws only. The regulator is plugged into the fan motor with a largish plastic plug.

Image

Regulator
Image
W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

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Ivanerrol
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Joined: Sat 12 May, 2007 3:21 pm
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Location: Melbourne

Re: How to replace blower fan brushes.

Post by Ivanerrol » Mon 06 May, 2013 10:48 pm

Remove the fan motor
Image

Look up into the chamber that the fan came from. Make sure there is no obstructions or dust – clean them out if there are any.

Image

Here’s the assembled motor on the bench.

Image

If you are simply replacing the motor with anew or second hand unit all you need to do now is put everything back in the order the items came out.
W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

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Ivanerrol
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Posts: 5557
Joined: Sat 12 May, 2007 3:21 pm
Model you own: w204
Location: Melbourne

Re: How to replace blower fan brushes.

Post by Ivanerrol » Mon 06 May, 2013 10:49 pm

Repairing the motor – i.e. changing the motor brushes.

There are two screws on the top of the motor that must be removed. Also remove the regulator if it’s still on the motor. The lug for the regulator is keyed so that it can only go in one way.

Image

After removing the two screws – as arrowed on the diagram, carefully slide the motor assembly away from the housing. You will be left with this.

Image

See that beer bottle? It took me just one bottle to do this whole job. Removing, repairing and replacing.

Arrowed in the next image is the clip that holds one of the brushes in (there are two brushes) The clip just comes off with a screw driver – careful, there is a spring underneath.

Image

Carefully pull the old brush out. Note the two clips and springs.


Image

The brush must be dunsoldered from this point

Image
W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

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Ivanerrol
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Posts: 5557
Joined: Sat 12 May, 2007 3:21 pm
Model you own: w204
Location: Melbourne

Re: How to replace blower fan brushes.

Post by Ivanerrol » Mon 06 May, 2013 10:50 pm

Image

Old techies will notice Ivanerrol’s folly in that he is using a boy to do a man’s job.

The soldering tool is tool small for the joint. When resoldering the new brush in there’s a good chance of getting a dry joint because not enough heat can be applied to the tag.

The Goldilocks choice.

One two small, one too big and the one in the middle just the right size for the job.

Image

Remove the old brush lead, clean the tag up and it should look like this. Leave some old solder on the tag – this “tins” the tag.

Image


Here’s the old removed brushes next to the new ones. No wonder they only work intermittently!

Image

Solder the new brushes into place

Image
W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

User avatar
Ivanerrol
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Posts: 5557
Joined: Sat 12 May, 2007 3:21 pm
Model you own: w204
Location: Melbourne

Re: How to replace blower fan brushes.

Post by Ivanerrol » Mon 06 May, 2013 10:51 pm

Position the new brush into place

Image


Replace the spring and holding clips

Image

Your done.

Reassemble everything back in the order you took things apart.

Test in the car.

The fans in the W202’s are quite quiet. You should not hear much wind noise. You should hear no rattles or clunking.

Open another beer.

Started this job at 16:30 finished by 17:20

I have never done this job before.

Looked it up on the net didn’t find any images – so decided to do some.

Spare parts wreckers quoted near $200.00 for a an old fan blower motor. Chances are the brushes would have been required in a second hand unit anyway.

The stealership price was in excess of a Thousand bucks.

To do this job you must have some knowledge of how to solder plus the right tools and equipment. Buying a soldering iron and some solder down at the local electronics store plus buying the brushes and replacing them yourself is still far cheaper than buying a second hand motor at a wreckers.
W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

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pastelgrey300D
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Re: How to replace blower fan brushes.

Post by pastelgrey300D » Mon 06 May, 2013 11:30 pm

Outstanding thread! Thanks for posting, there is a possibility that we may end up with a 202 or 210 in the future so great to see threads like this. And proof that there is still plenty of the old DB engineering DNA in these cars, more modern cars would have one way tabs and catches or have everything pressed together instead of screws... :occasion5:
David
1967 W111 230S - Horizonblau
1965 W110 190c - Mittelrot
1967 W110 200D - Weiss (work in progress)
+ other classics

redlaser
Finnie
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Model you own: w126
Location: Narre warren Melbourne

Re: How to replace blower fan brushes.

Post by redlaser » Thu 09 Apr, 2015 10:24 am

I'm about to replace the blower in a W126 series 2...do u know if the procedure is the same as above?

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Tony From West Oz
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Re: How to replace blower fan brushes.

Post by Tony From West Oz » Thu 09 Apr, 2015 11:05 am

I am sure that removal would be different but the actual brush replacement would be similar. There is likely to be a different brush retainer system too.
Soldering the new brushes in should be the same.

Why not do a tutorial on the brush replacement for W126's?

Tony
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

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Ivanerrol
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Re: How to replace blower fan brushes.

Post by Ivanerrol » Thu 09 Apr, 2015 7:26 pm

W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

redlaser
Finnie
Posts: 294
Joined: Tue 02 Jun, 2009 5:38 pm
Model you own: w126
Location: Narre warren Melbourne

Re: How to replace blower fan brushes.

Post by redlaser » Fri 10 Apr, 2015 9:34 am

Thanks muchly for info...I had searched for several days and did not come on the site...guess a "squeaking blower " were the key search words!

tsharkey
C 111
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Joined: Sat 25 Apr, 2009 10:32 am
Model you own: w123
Location: Melbourne, Vic

Re: How to replace blower fan brushes.

Post by tsharkey » Wed 29 Apr, 2015 11:12 pm

Ivanerrol wrote: Started this job at 16:30 finished by 17:20

I have never done this job before.
Clearly I didn't have the performance enhancing drugs you were drinking as it took me 90 minutes ...

Great post and thankyou for going to the trouble, yet another item on the W202 fixed.
W123 1981 300TD - Family Kid mover
W202 1998 C250D Factory OM605A Turbo - Partner's daily driver
W123 1982 300CD Retro fitted OM617A Turbo - Mine
W123 1984 300TD 5 Speed Manual, to teach the kids how to drive
W123 1982 300TD Factory OM617A Turbo (Hans) - Project
W123 1985 230TE - Brother's
W123 1985 300D - Sister in Law's
1962 S-Series Valiant (Tho Daimler & Chrysler divorced, still part of the extended family)

Past benzes
W114 1969 250CE - PO put in an M110 transplant and nearly sent me around the bend
W123 1981 300TD - "Matilda" - RIP hit front side & rear but left my brother + niece A-OK

Current Projects
Coupe restoration, Turbo Wagon freshen up

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Ivanerrol
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Re: How to replace blower fan brushes.

Post by Ivanerrol » Wed 29 Apr, 2015 11:45 pm

tsharkey wrote:
Ivanerrol wrote: Started this job at 16:30 finished by 17:20

I have never done this job before.
Clearly I didn't have the performance enhancing drugs you were drinking as it took me 90 minutes ...

Great post and thank you for going to the trouble, yet another item on the W202 fixed.
Probably because I have all the proper tools and have been doing electronic soldering works for 45 years. :whistle:
W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

176bob
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Posts: 18
Joined: Tue 27 Nov, 2012 8:41 pm
Model you own: w202

Re: How to replace blower fan brushes.

Post by 176bob » Thu 30 Apr, 2015 12:17 pm

Absolutely spot on, great tutorial. Thank you. Bob.

piperjon
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Posts: 84
Joined: Thu 06 Jun, 2013 8:34 am
Model you own: w202
Location: Sunny Corner N.S.W.

Re: How to replace blower fan brushes.

Post by piperjon » Sat 10 Dec, 2016 5:03 pm

Hello
I have been trying to find on the internet a set of brushes for my blower motor W202 C180 1997 Merc. But doesn't seam to be any good. Does any one know where I can pick up a pair??
I suppose ring Mercedes that maybe no loner made like a few thing you need.

As I asked if any person know where I can buy a pair. Please let me know.
All the best.
John

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Ivanerrol
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Joined: Sat 12 May, 2007 3:21 pm
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Re: How to replace blower fan brushes.

Post by Ivanerrol » Sun 11 Dec, 2016 10:24 pm

Try Ebay UK. That's where I source them.
W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

piperjon
S Class
Posts: 84
Joined: Thu 06 Jun, 2013 8:34 am
Model you own: w202
Location: Sunny Corner N.S.W.

Re: How to replace blower fan brushes.

Post by piperjon » Fri 22 Sep, 2017 8:47 am

Hi guy's.
thanks Ivanerrol for showing use who have trouble with the blower fan as I did. Added the new brushes and now it works well. Thank you for all the pictures from start to finish.
Great stuff.
Cheers John :wav:

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