Mercedes Benz Tech Tips

Mercedes Hard Start - Overload or Over Voltage Protection Relay


All of the sudden my Mercedes 300E is very hard to start, and runs poorly. This seemed to happen right after I jump-started my battery. What's wrong?
 
The primary culprit is usually the over voltage protection relay. The relay might have blown due to excessive voltage generated in your vehicles electrical system when you hooked up the jumper cables. However, the relays do go bad all by themselves.
 

On W124 and W201 chassis, the relay is located in back of the plastic cover behind the battery. On W126 chassis it is located between the 2 firewalls underneath the hood. On W107 chassis it's located behind the right kick panel.

Check the 10 amp fuse on top of it first. If it is blown, replace it. If it is good, check the socket that that the fuse sits in for corrosion. Clean and/or replace as necessary.

Mercedes Overload Protection Relay
 
The relays were also known to have weak solder joints from factory and go prematurely bad, but chances are the relay was doing its job protecting your car's control units, and give thanks that it did. The components it was protecting are expensive.
 
What does the relay have to do with the way my car runs?
The Mercedes over voltage protection relay provides voltage to the ABS and Mercedes engine control units. In the case of hard start, when you cut off the voltage supply to the engine control unit, you loose all of your cold idle circuits. This includes the idle and cold fuel enrichment circuits. The fuel enrichment circuit is used to start you engine when it is cold. The idle circuit is used for increased rpm when the engine is cold, and curb idle when the engine is warmed up. When these circuits do not operate the engine can still run, but very poorly. Plain and simple - the control units can not operate the systems of your car without voltage. No voltage equals all kinds of derivability problems.
 
Tech Tip: When checking voltage at the pins of the overload protection relay pin 30 is hot with the key on and pins 87 are the output voltage to the control units. If the relay is blown there will not be voltage present at pins 87.
 
 

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