surlyoldbill
Well-known member
{NOTE: Subsequent to this excellent hack, Mercedes upgraded the glow plug module to include circuit breaker type links that are resetable. It is available for around $110. }
Upon learning that the modules fail because of a blown internal fuse, I decided to open my old one up to see if I could hack the design and create leads to external (replaceable) fuses. The donor was from a 2003 Sprinter.
Upon inspection, it appeared to be a one-piece unit. I chose a japanese style saw to cut away the back and top to see inside. I dabble in japanese carpentry, and have better control with one of these saws than a power tool such as a dremel with a saw blade attachment, my second choice for the procedure.
With the back and top cut off, I found out how the module was made.
The module is made by slipping the electronic parts plate in from the front, where it is caught by tabs on the top bottom and sides, then it is sealed with what appears to be black silicone, making it look like it is a one-piece mold, which it is not. The module can be taken apart by cutting the silicone with a razor, and prying open the tabs, allowing the module to be slid forward out of the enclosure.
The next step will be determining the proper size fuses, and soldering in jumper wires to a 5-bank fuse holder, one for each glow plug. The design is a little funny, because though one side of the metal fuse is blown, the other remains intact and would thus allow current to flow (that is a one-piece metal tab with a slot in the middle). I am not familiar with this style of "partial" fuse.
Upon learning that the modules fail because of a blown internal fuse, I decided to open my old one up to see if I could hack the design and create leads to external (replaceable) fuses. The donor was from a 2003 Sprinter.
Upon inspection, it appeared to be a one-piece unit. I chose a japanese style saw to cut away the back and top to see inside. I dabble in japanese carpentry, and have better control with one of these saws than a power tool such as a dremel with a saw blade attachment, my second choice for the procedure.
With the back and top cut off, I found out how the module was made.
The module is made by slipping the electronic parts plate in from the front, where it is caught by tabs on the top bottom and sides, then it is sealed with what appears to be black silicone, making it look like it is a one-piece mold, which it is not. The module can be taken apart by cutting the silicone with a razor, and prying open the tabs, allowing the module to be slid forward out of the enclosure.
The next step will be determining the proper size fuses, and soldering in jumper wires to a 5-bank fuse holder, one for each glow plug. The design is a little funny, because though one side of the metal fuse is blown, the other remains intact and would thus allow current to flow (that is a one-piece metal tab with a slot in the middle). I am not familiar with this style of "partial" fuse.
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