Rear Tail light issues W204

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
Posts: 5967
Joined: Sat 12 May, 2007 2:21 pm
Model you own: w204
Location: Melbourne

Rear Tail light issues W204

Post by Ivanerrol » Mon 12 Aug, 2019 6:18 pm

There is a "design" fault in the W204 tail light circuit board.
This has been a contentious issue for many years.
It was the subject of a compulsory recall in the USA for safety reasons - no deal in Oz.

Basically the current load through the earth cable onto the circuit board connection is too high for the design
The connector overheats, melts the plastic surround and causes oxidation. Eventually no earth to the taillights.
here's an image
Image
back side image
Image

Its a barrow full of $$$$ to have this rectified at the stealers

My work around next thread
W211 - E240
W204 - C280
Departed
W202 - C200, C180, C180
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, E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

Ivanerrol
Mercedes Demigod
Posts: 5967
Joined: Sat 12 May, 2007 2:21 pm
Model you own: w204
Location: Melbourne

Re: Rear Tail light issues W204

Post by Ivanerrol » Mon 12 Aug, 2019 6:27 pm

Cut the brown earth wire off the circuit board connector
Image

you can see the little bit of wire that's been cut on the far left of the connector.

Next, either solder on or do as I did connect a new brown wire on to the earthing plate on the circuit board.
I drilled a small hole, connected a brown wire to a tag connector and used a self tapper with a spring washer and conductive paste attached it to the earthing plate.
Image

Fed the new brown wire out of the circuit board and used a screw type quick connector to join to the original earthwire feed.
Image

Next. removed all the bulbs. Found some corrosion under each of the +ve bulb connectors - cleaned them all up.

No more failed lamp indications in the instrument cluster and the tail light bulbs are now shining much brighter
W211 - E240
W204 - C280
Departed
W202 - C200, C180, C180
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, E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

User avatar
Bartman4800
300 SLR
Posts: 2118
Joined: Fri 10 Oct, 2008 12:10 am
Model you own: w111
Location: Perth WA

Re: Rear Tail light issues W204

Post by Bartman4800 » Mon 12 Aug, 2019 6:28 pm

Good fix...except for the screw connector.

No access to solder the joint and put heatshrink around it?

Bart
1963 220 Sb Sedan "Kermit" (Australian Assembly)
1960 220 Sb Sedan "Zum Schlachten" (Early German Assembly, with a torsion bar spring for the bonnet) - Stored in Country WA
1981 Subaru Brumby 1.8 with Weber and 5-speed box "little utie" - Sold to another enthusiast!
2006 Ford Focus "daily driver"
2002 VW Passat V6 30V Station Wagon (SOLD - This car into a money pit)
2011 Kia Sportage "Missus commuter Bus"
2002 Mitsubishi Rosa Bus (converting it to a motor home)

Ivanerrol
Mercedes Demigod
Posts: 5967
Joined: Sat 12 May, 2007 2:21 pm
Model you own: w204
Location: Melbourne

Re: Rear Tail light issues W204

Post by Ivanerrol » Mon 12 Aug, 2019 7:24 pm

Worried about melting too much plastic.🙄
W211 - E240
W204 - C280
Departed
W202 - C200, C180, C180
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, E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

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