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  #1  
Old 02-17-2009, 03:34 PM
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Question 85 300D OVP Relay - old one has 5 pins, new one has 6

Someone has to have been down this road...

Replacing the OVP relay thats under the passenger dash (no tach, AC etc.). The PN on it is 1265404745. Bought it, have it in hand.

http://catalog.peachparts.com/searchitem.epc?cookieID=2KV0K0NZN2L30WPQBU

But the new one has six pins. The old relay, and the socket have five.

Looking at the schematic, I think I could remove the offending pin from the new relay, its redundant with another pin...but Im reluctant to hack into $50 parts recklessly.

Who's been here before?

dd

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-------------------------------
'85 300D, 'Lance',250k, ... winter beater (100k on franken-Frybrid 3 Valve Kit)
'82 300D, 'Tex', 228k body / 170k engine ... summer car
'83 300TD Cali Wagon 210k, wife's car
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  #2  
Old 02-17-2009, 03:54 PM
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My '85 300D-T (W123) and my '87 300D Turbo (W124) have similar wiring for the OVP but whether the two have the same pin configuration I do not know. I don't have a spare for the '85 and the one in the car is buried of course, but I do have a spare for the '87. It's a 201 540 08 45. It has five metal pins and one plastic alignment pin. Is there any chance that you were sent the wrong part?

********AZ says that your 126 540 47 45 and my 201 540 08 45 are interchangeable. They list the former for the '85 W123 and the latter for the '87 W124.

EPC lists 201 540 08 45 for both the '87 W124 and the '85 W123. Five pins plus a plastic pin.

Which is the "offending" pin on your newly-purchased OVP?
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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

Last edited by Jeremy5848; 02-17-2009 at 04:05 PM.
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  #3  
Old 02-17-2009, 03:59 PM
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No - the part matches the fast lane pictures 100%. Its what I ordered.

The old part has 4 metal pins, 1 plastic one, and a blank space across from the plastic pin.

The new part, which is 201 540 08 45 has 5 metal pins and one plastic one. when I enter the old part # 126 540 47 45 into fastlane, 201 540 08 45 is what comes up.

Hmm...
__________________
-------------------------------
'85 300D, 'Lance',250k, ... winter beater (100k on franken-Frybrid 3 Valve Kit)
'82 300D, 'Tex', 228k body / 170k engine ... summer car
'83 300TD Cali Wagon 210k, wife's car
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  #4  
Old 02-17-2009, 04:05 PM
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We're Victims of Deutschlander Standardization (across the model lines)

Yeah, [Freaked Me Out when I opened the Box] (this is on a '90 W124)
OLD OVP has: 7 pins total (1 locator pin,plastic/6 actual pins,metal)
+ 1 10 Amp fuse in the top.
NEW OVP has: 9 pins total (1 locator pin,plastic/8 actual pins,metal)
+ 2 10 amp fuses in the top.

ALL the NEW Pins have homes in the old female plug (Some of them are
unused)
The extra fuse actually protects an additional circuit not covered by the OLD
OVP.

BUT,You shouldn't have/need to "Break Off" or "Cut Off" PINS!
Triple Check that you've been given the correct OVP for your application.
Below should be the KAE (manufacturer) OVP relay for your MB.

If all the NEW pins fit into an existing location hole,You're O.K.
Even if some of the pins have no female contacts.
Attached Thumbnails
85 300D OVP Relay - old one has 5 pins, new one has 6-screenhunter_07-feb.-17-15.39.gif   85 300D OVP Relay - old one has 5 pins, new one has 6-screenhunter_08-feb.-17-15.39.gif  
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Last edited by compress ignite; 02-17-2009 at 04:17 PM.
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  #5  
Old 02-17-2009, 04:20 PM
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Triple checked. I have Kaehler 201 540 08 45 in my hand as the new part. The old one is 126 540 47 45.

I guess the real problem is my socket only has 5 pins. The relays both have schematics on the side - they are identical except that the offending pin that has been added is a duplicate of another pin...and does nothing as far as I can tell.

Man, its never easy! I guess its my own fault thinking I could make any sort of repair in an hour before I need to go somewhere.

FWIW, the old one is definitely broken, the 10A fuse is good, but I can hear the contacts flopping around inside the relay. Makes sense - the tach sprung to life once or twice since I have owned the car, accompanied by a buzzing sick relay type noise.

dd
__________________
-------------------------------
'85 300D, 'Lance',250k, ... winter beater (100k on franken-Frybrid 3 Valve Kit)
'82 300D, 'Tex', 228k body / 170k engine ... summer car
'83 300TD Cali Wagon 210k, wife's car
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  #6  
Old 02-17-2009, 06:46 PM
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If the "extra" pin is labeled "87" then it is safe to cut off. That number ("87") is German for "relay contact." It's probably defined as part of the DIN standard. Since the OVP in your car is warm and dry inside the passenger compartment, you don't even have to seal off the hole.
__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970
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  #7  
Old 02-17-2009, 10:50 PM
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cool. it indeed is an extra 87 pin. i guess ill have that pin off tomorrow and see what happens.

i could also 'go fish' in the local yards for an '85 that happens to have a working relay...but i feel the chances are low.
__________________
-------------------------------
'85 300D, 'Lance',250k, ... winter beater (100k on franken-Frybrid 3 Valve Kit)
'82 300D, 'Tex', 228k body / 170k engine ... summer car
'83 300TD Cali Wagon 210k, wife's car
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  #8  
Old 02-17-2009, 11:03 PM
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Let us know if it works, we may have to do the same thing one day.
__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970
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  #9  
Old 02-18-2009, 03:41 PM
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Thumbs up Tach Works!

I extracted the redundant pin like you would pull a tooth. sort of worked it back and forth with pliers till it came out.

Popped new relay in, started car, and tach snaps to attention. Woohoo!

I have some pics Ill put up later after I button it up.

I am excited, the AC doesnt work in this car, even after the PO had 'everything done' and it even holds a charge. I think I know why now :-) Not that I can test AC right now...it would still be warmer than outside air :-)

So, 85 300D owners, be prepared to 'modify' the new relay and you will be in business.

dd
__________________
-------------------------------
'85 300D, 'Lance',250k, ... winter beater (100k on franken-Frybrid 3 Valve Kit)
'82 300D, 'Tex', 228k body / 170k engine ... summer car
'83 300TD Cali Wagon 210k, wife's car
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  #10  
Old 02-18-2009, 05:57 PM
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A/C testing in Artic conditions

DieselDan44,

Turn on the Defrost function,this will engage the A/C compressor
(to provide De-Humidification during defrost)
If you've got a Gauge Set you could hook it up and check the readings.
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  #11  
Old 02-18-2009, 10:14 PM
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Quote:
Originally Posted by compress ignite View Post
DieselDan44,

Turn on the Defrost function,this will engage the A/C compressor
(to provide De-Humidification during defrost)
If you've got a Gauge Set you could hook it up and check the readings.
thanks! ill give it a shot. i have a gauge set that Ive never used.
__________________
-------------------------------
'85 300D, 'Lance',250k, ... winter beater (100k on franken-Frybrid 3 Valve Kit)
'82 300D, 'Tex', 228k body / 170k engine ... summer car
'83 300TD Cali Wagon 210k, wife's car
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  #12  
Old 02-18-2009, 10:18 PM
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Posts: 2,042
Of course there's a catch

Went on a highway drive tonight with the new tach. When I get to 2000 RPM, I now get an electronic whine that ends abruptly at about 2300 rpm.

So it's related to the EGR. It sort of sounds like something under the dash electronic is in distress. Ughhh.

How can I get rid of this? Anyone know? May be a new thread...
__________________
-------------------------------
'85 300D, 'Lance',250k, ... winter beater (100k on franken-Frybrid 3 Valve Kit)
'82 300D, 'Tex', 228k body / 170k engine ... summer car
'83 300TD Cali Wagon 210k, wife's car
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  #13  
Old 11-16-2014, 04:58 PM
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I just went down the same road today. Tach stopped, then blower motor. I took out the overload relay and I can hear something rattling inside.

Apparently we have the "euro" version with only four pins. I have a new 50 dollar five pin overload relay. Like yours, it will not fit. They don't make the four pin version anymore.

When you extracted the extra pin did that work in the long term? I've got the new one here and was thinking about doing the same thing.

Thanks!
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  #14  
Old 02-12-2016, 06:19 PM
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I wanted to see if anyone could provide a follow-up on this thread. PW Glidewell did you eventually take the plunge and pull one of the pins? I'm about to do the same for my '84 300D after receiving a Kaehler 201 540 08 45. Any problems in the long run anyone?
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  #15  
Old 02-12-2016, 07:17 PM
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I cut my pin off I don't think you can pull it out cleanly, My tach wasn't working, now it does. It's been a year with no problems. ('85 300D).

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