Tag Archives: mercedes

Track Truck – first repair attempts

At the beginning of the week, the new truck broke down outside of town. After some fighting we got it back to the garage for diagnostics.

Once running again after purchasing a new battery charger and hours of fiddling, it was clear the battery was junk.

Testing battery and charging system performance.
Testing battery and charging system performance.

It looked like a cheapo battery, and it had no date indicators on it to clue me in to it’s age. Regardless…

It's dead, Jim.
It’s dead, Jim.

Once a new battery was obtained, it was then possible to truly test the remainder of the charging system, namely the alternator.

Having started up the van easily with the new battery, checking voltage across the terminals showed that the rest of the charging system was in failure. This could have killed the battery during our repeated jump-starts to get it back home. Might have just been cheaper to tow it (note to self).

Lack of charging can be result of multiple issues other than a bad alternator in the Sprinters. The most common culprit are bad grounds. There are several on the driver (left in USA) side of the engine room that need to be checked.

  • main chassis ground just above the battery negative terminal
  • engine main ground on the left side engine mount, connected to the frame rail in the same area
  • control system and accessory points below the battery near the headlamp

Having checked all those and cleaned them for good measure, the next easy win is checking the alternator fuse. On the sprinter there is a large plastic block bolted to the battery cable lead connector. From that block runs several high-amp wires (red) and one very large black wire, which heads to the alternator (this is the main charging feed). Inside this block there are plastic fuses of various amperage, high amperage, including a 200A fuse on the charging system side. This fuse is next checked for continuity to ensure that it is not open, and thus causing the charging system to fail.

Having inspected that, and seeing that it is in tact, the next avenue of investigation is the alternator itself.

Following the acquisition of some TORX Sockets (female, not male), sizes E12 and E6 where required, and about 1 hour of pulling parts to access top and bottom of the alternator, the item was removed.

Turbo charger as seen from top in Dodge 3500 Sprinter (intake and outflow piping removed).
Turbo charger as seen from top in Dodge 3500 Sprinter (intake and outflow piping removed).
Dodge 3500 Sprinter intake and turbo outflow parts
Dodge 3500 Sprinter intake and turbo outflow parts
Dodge Sprinter 2500 90Amp alternator
Dodge Sprinter 2500 90Amp alternator

Tomorrow I will be picking up a rebuilt alternator for around $210. Hopefully that brings the fun-van back to life!

$518 later, a new pair of tires for the CLK

OUCH. Pricy tires! But like most things in life, the true cost of owning a vehicle can be a lot more than just the ‘purchase price’. $1100 for a set of tires, $1300 for a set of decent (not great) wheels, $400 for sport shocks… $200 for spark plugs (takes 16 multi-tip Platinum).

In the end, a tire I was not really comfortable driving on with kids in my car, has been replaced and I can move on with life.

Still.. $518 unplanned dollars…. (+ tax) was a bit hard to swallow!

Yeah! Resurected Audio!!!!

It all started at 5:00AM this morning when the mail server at work died.  One of our few single-power supply systems still in use (we have a nice 4 SAS dual-power RAID 10 system to replace it scheduled for deployment Aug 21).   At any rate, the CRAPPY Ablecom SP302-1S power supply gave up (2nd one in 6 months, and it looks like a 3rd one just started to show signs of dying an hour ago) and one of our most critical systems was down!

After getting one of my engineers in route, I knew I’d have some time to look at the ripped up car in my garage.  With time on my hands, I flipped through some axillary tools sets, locating a pair of flat radio removal tools (designed for Alpine head units).  Pondering the possibilities of possibly manufacturing my old keys, I set about cutting up the metal. At least it was something to keep me busy.

Home made radio keys
Home made radio keys

It took a few attempts to find the right angles, but I did finally managed to get he head unit (aka Command Unit) removed!!

Deck removed!
Deck removed!

And, as I suspected, there it was yet ANOTHER fuse.   I’d recalled this morning from projects past, that most of the head units in MBZ had a fuse on the back of them.   And so does this one:

The 4th fuse (10 AMP)
The 4th fuse (10 AMP)

I always have an ample supply of fuses (from careers past).  With hope alive in my heart, and my cell phone by my side waiting to hear from my team, what the prognosis was for our mail server..   I re-attached the mass of plugs (3 analog, one fiber optic CAN, and the antenna);

The many wires of a German radio
The many wires of a German radio

slipped it into the dash and:

Radio asking for the secret access code
Radio asking for the secret access code

CODE!  I have the code prompt.  Expensive disaster averted!   Being the fastidious keeper of information that I am, I had the code at hand, and within a few seconds….  was rewarded with the sounds of my favorite local FM station.

TUNZ!
TUNZ!

At least the day did not start out as a TOTAL loss!

My guys called me back shortly after this, and let me know that the server was dead, totally dead, no power.  I instructed them to pull the system from our rack and bring it home for recovery.  I hastely re-assembled my car, got dressed, stopped by Krispy-Kreme to buy them coffee and doughnuts, then rocketed into the office to direct the recovery effort (which is still underway).

At least I could listen to the music for a little while. 🙂

Boooooooo BOSE dies in my car… :(

Arg.  Instead of plowing into the tail-end of the jerk that cut me off yesterday, I am rewarded with the stereo system in my car, dying.

Why and what happened?  I’m still trying to sort that out.  But I do know that whatever DID happen to my car’s audio system, it happened when I had to get deep into the brakes to avoid a rather ‘rude’ driver.  Right then the radio cut.  I thought maybe a bad commercial break or something.   Looked down at the radio a few seconds later and… NOBODY HOME.

I finished my errands yesterday, with only the sound of the 24 valve 4.3L V8 to serenade me.  Now..  there is nothing wrong with the nice sound of a powerful V8 engine (OK.. 285 HP powerful… not too bad for a motor that 262 CID motor that idles like glass at 400 RPM, try that with your S***block Chevy! hahaha) .   At any rate.. BOSE dead.

I parked it in the garage this morning and took the ML to work.  It needed some gas (it ALWAYS needs some gas, powered by the same V8 engine, but pushing AWD and a brick of a body, it’s pretty harsh on the Premium fuel), but I didn’t want to spend the 1 hour commute to work listening to hushed sounds of wind and the expansion joints of the highway.

Upon returning home, I enlisted the assistance of my helper (aka son) and we took the rear end of the car’s interior apart.  The majority of the audio system is located back there so it seemed a good place to start.

Removing all interior trunk interior panels.
Removing all interior trunk interior panels.

Sadly, after checking both fuse blocks, and the fuse on the main audio amp (all good), I’m out of ideas for the quick-fix on the system.  Looks like I’ll have to get the special tools to remove the factory head unit and see if maybe the plug on the back of that came loose during braking.   I hope so…  sad if it happend, happy for me if I can fix it without spending $2500 for all new audio.  These factory systems are all CAN-BUS fiber optic networked.  Can’t just ‘toss in’ a new head unit.

Stripped bare.  Amp on left, CD changer at the top, LASER interface on the right.
Stripped bare. Amp on left, CD changer at the top, LASER interface on the right.

Happy happy, joy joy.

Formula 1 Season Opener – Australia

2009 brings in a lot of rules changes to Formula 1

  • no more grooved tires

    Tyres
    After 10 seasons on grooved tyres, Formula One racing returns to slicks in 2009, as part of moves to increase the emphasis on mechanical rather than aerodynamic grip. With no grooves, grip will increase by around 20 percent, bringing a significant performance gain. However, that gain will be offset by the vastly reduced downforce levels of the revised aerodynamic regulations (see below). The overall effect should be reduced performance through high-speed corners.

  • massive aero overhaul to improve passing

    Aerodynamics
    Along with slick tyres, this is the biggest area of change for 2009. Downforce will be dramatically reduced and the cars’ bodywork will appear much cleaner, thanks to new dimensional regulations that effectively outlaw extraneous items such as barge boards, winglets, turning vanes and chimneys on most areas of the car.

    As well as reducing overall aero performance, the revisions are also designed to increase overtaking by making the car less susceptible to turbulence when closely following another driver. The most obvious changes are to the front and rear wings.

  • New electric (slightly related to a hybrid) electric boos system

    Kinetic Energy Recovery Systems (KERS)
    From 2009 teams have the option of employing a KERS to boost their car’s performance. As its name implies, a KERS recovers the (normally wasted) kinetic energy generated by the car’s braking process. This energy is stored using a mechanical flywheel or an electrical battery and then made available to the driver, in set amounts per lap, via a ‘boost button’ on the steering wheel. Under the current regulations the power gain equates to around 80 horsepower, available for just under seven seconds per lap. This could be worth several tenths of a second in terms of lap time, but the weight and packaging of the system – and its impact on the car’s weight distribution – also have to be taken into account.

  • more interesting technical here

Bottom line is that the new cars are pretty darn ugly, with huge front aero wings but tiny rear wings.  It’s looks way out of proportion.  This is one of the changes they made to cleanup air behind the cars to encourage passing.  In this first race of the season it seems to have done just that.

Round 1 of the season presented a bunch of things that seemed like ‘upsets’ to me.  One of the more surprising things was the utter dominance of the new BrawnGP team.

Another was the amount of passing.  That really made for an interesting race, much more interesting than the Micheal Schumacher Show of seasons past.

It also seemed that the new front wings were quite fragile, many were damanged in the first lap of the race.  It was obvious that the teams forsaw this issue and spent plenty of time training in the pits to handle swapping out the noses.

You can get the rules changes highlights on the Official Formula 1 Website, as well as detailed updates last night’s (well, this mornings) race.

I wish BrawnGP luck in it’s first year, basically running last year’s 2008 Honda team but with Mercedes Power.