|
|
|
|
|
|||||||
 |
|
|
LinkBack | Thread Tools | Display Modes |
|
#1
06-18-2006, 12:53 AM
|
||||
|
||||
|
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)
These pictures are from replacing the evaporators in my Daughters 1983 240D and my 1982 300TD. Not every little step is included. As you progress you will figure things out. This is not a terribly difficult job. Just time consuming. AC knowledge is required for this job and a 609 license is worth while. Not mandatory but preparing for the test teaches you a tremendous amount about the AC system.
Notice some pictures are labeled 300TD, 240D and 300TD/240D. I am trying to show pictures that are specific to the model listed. IF I have not listed a car then it applies to both. What is specified for the 300TD will apply to the 300D and 300CD usually. This is for a “Automatic Climate Control III” for the 300TD as specified in the Mercedes Service Manual. And the “Heating/Ventilation and Air Conditioning I” as specified the Mercedes Service Manual for the 240D. The only difference in the 240D system is the car has the R-4 compressor not the York unit shown in the Service Manual. Of course disconnect the battery, drain the radiator and you will have to recover any freon in the AC system. Note, when looking at the pictures if the car is maroon in color it is the 240D. Signal red ( stop sign red) it is the 300TD Any recommendations for this post will be appreciated. Dave I have edited this post to make corrections so that the names of various parts match the Service Manual name, and a few spelling corrections Page 1
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 12-27-2006 at 03:41 PM. 
|
|
#2
06-18-2006, 12:54 AM
|
||||
|
||||
|
001 Remove Mercedes symbol, this is not really necessary.
002 Peel the horn cover off 003 Pull the center of the cover off hub 004 After removing bolt, Mark the shaft wheel relationship with a punch. 005 Remove ashtray Page 2
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 12-27-2006 at 03:21 PM.
|
|
#3
06-18-2006, 12:54 AM
|
||||
|
||||
|
006 Remove center console carpet and remove screw
007 Remove ashtray bracket mounting screws 008 Lift front of wood trim above shifter and slide to the rear to remove 009 Disconnect wires 010 Slide towards rear to protect the pin, disconnect switch wires Page 3
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 12-27-2006 at 03:28 PM.
|
|
#4
06-18-2006, 12:54 AM
|
||||
|
||||
|
011 Pull radio
012 Label radio wires 013 Pull off AC control knobs 014 Use socket to remove AC control nuts 015 Pull AC panel and disconnect light units Page 4
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 06-18-2006 at 01:06 AM.
|
|
#5
06-18-2006, 12:54 AM
|
||||
|
||||
|
016 Pull switch out from the rear
017 Pull all switches and remove the wire harness 018 Using your fingers in the outside holes, push the wood trim out from behind 019 Wood trim lifts at bottom first then out 020 Disconnect the temp dial wires using your fingers. 2 harnesses Page 5
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 06-18-2006 at 01:07 AM.
|
|
#6
06-18-2006, 12:54 AM
|
||||
|
||||
|
021 Push in the top tab and remove the dial by pushing the unit into the console
022 300TD/240D. Remove the outboard switches to remove the screws 023 Remove both front seat inboard slide bolts in rear tunnel 024 Remove drivers seat back panel. Unscrew it then slide the panel down. Or remove the entire driver seat. 025 Remove the bolt holding the drivers seat armrest Page 6
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 12-27-2006 at 03:29 PM.
|
|
#7
06-18-2006, 12:55 AM
|
||||
|
||||
|
026 Remove screw covers on both under dash panels
027 Remove screws 028 Remove under panel side screws 029 Remove under dash panels 030 Drivers side under dash panel, side screw Page 7
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 06-18-2006 at 01:11 AM.
|
|
#8
06-18-2006, 12:55 AM
|
||||
|
||||
|
031 Remove center consol carpet screws
032 Lift center consol from the rear. Watch top center of consol and dash clearance. 033 Guide center consol carpets while lifting. 034 Guide center of consol over shifter. 035 If you can’t remove the center consol. Disconnect the tabs holding the carpet, 4 total ( Note: The manual does call for the driver seat to be removed. For the removal of the center consol, the side carpets are the reason) Page 8
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 06-18-2006 at 01:59 AM.
|
|
#9
06-18-2006, 12:55 AM
|
||||
|
||||
|
036 Center console removed. The AC control panel is broken on this car.( I glued the unit together, A new unit has to come from Germany)
037 Remove the floor heat dust under the drivers feet 038 Removing the floor duct, drivers side , continued. 039 Remove the cable harness on the drivers side of the floor duct 040 More center console pictures Page 9
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 12-27-2006 at 03:29 PM.
|
|
#10
06-18-2006, 12:56 AM
|
||||
|
||||
|
041 Removing AC control bracket, (this will not normally be removed, it is pop rivited to the evap box. Switches must be removed from the panel)
042 ID wire harness to switch connectors 043 ID wire harness to switch connectors, continued 044 Remove bulb spider for center console lights 045 Clips that hold the Bowden cables to the side controls Page 10
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 12-27-2006 at 03:30 PM.
|
|
#11
06-18-2006, 12:56 AM
|
||||
|
||||
|
046 Plastic panel on Bowden cable mechanism. Positioning picture for repositioning after
unbolting mechanism 047 Wire harness to control 048 Remove oil line and loosen speedometer cable in engine compartment so you can pull out instrument cluster far enough to remove speedometer cable. Remove wires 049 Pull off light switch 050 240D idle knob. Pull knob off straight back ( it’s hard) and unscrew chrome ring Page 11
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 06-18-2006 at 02:03 AM.
|
|
#12
06-18-2006, 12:56 AM
|
||||
|
||||
|
051 Unhook parking brake cable chain.
052 Unscrew speaker grill screws on both speakers and remove grills 053 Remove push clips center pins then base. 3 on bottom and 4 on top 054 Remove glove box light and disconnect wires 055 Remove glove box. Pry the top below the striker plate. Then remove the light wires Page 12
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 06-18-2006 at 02:04 AM.
|
|
#13
06-18-2006, 12:57 AM
|
||||
|
||||
|
056 Pry the A pillar molding off the A pillar Use a wide metal or plastic tool. Pry at the
bottom then the top 057 Pry at the top then move the bottom of the trim towards the center of the car. Watch out for the speakers. 058 Remove the speaker mount bolts and speakers 059 240D Disconnect the center vent cable from the vent mechanism. 060 Remove the drivers side lower dash mount bracket completely. Note the screw washer combination and orientation of bracket Page 13
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 06-18-2006 at 02:05 AM.
|
|
#14
06-18-2006, 12:57 AM
|
||||
|
||||
|
061 Remove the passenger side lower mount bracket. Note the same info as above
062 Disconnect both speaker wires from the dash. 063 Remove the center support bracket completely so it does not hit the evap box Remove the dash from the passengers side first and move it out the passengers door. You will have to lift the dash off the defroster tubes on the evap box. Once lifted off them, it will come out. Watch the turn signal stick. Don’t break it. Don't twist the dash as this may cause cracking. One word about reinstalling the dash. As you install the dash, the lip of vinyl at the front of the dash next to the windshield will curl up and make it difficult to get under the windshiled rubber. Using the same flat tool used to remove the A pillar moldings works well. Hold the dash in position and slie the lip under the weather strip. 064 300TD Replace the foam tube under the dash, I used a plastic unit 065 300TD Move the amp wire harness Page 14
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 06-18-2006 at 12:22 PM.
|
|
#15
06-18-2006, 12:57 AM
|
||||
|
||||
|
066 300TD Remove the amp setup to allow the evap box to clear
067 300TD Center console area. 068 300TD Center console area upper section 069 300TD Holding the center area wire harnesses 070 300TD the center console area switches going though the wire locking strap Page 15
__________________
1970 220D, owned 1980-1990 1980 240D, owned 1990-1992 1982 300TD, owned 1992-1993 1986 300SDL, owned 1993-2004 1999 E300, owned 1999-2003 1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD 1988 560SL, 100,000mi, owned since 1995 1965 Mustang Fastback Mileage Unknown(My sons) 1983 240D, 176,000mi (My daughers) owned since 2004 2007 Honda Accord EX-L I4 auto, the new daily driver 1985 300D 264,000mi Son's new daily driver.(sold) 2008 Hyundai Tiberon. Daughters new car Last edited by dmorrison; 12-27-2006 at 03:30 PM.
|
|
| Bookmarks |
|
|
Linear Mode
