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  #16  
Old 06-17-2006, 11:57 PM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
071 300TD Right side wire harness holder
072 300TD Remove the center connection under the vacuum switchs
073 300TD Picture for identifying plastic tubes color codes
074 300TD Picture for more plastic tube color ID
075 300TD Vacuum tubes to center vent element


Page 16
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-071-300td-right-side-strap-connectors.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-072-300td-remove-center-conection-under-vac-swt.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-073-300tdcolor-code-vacuum-tubes.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-074-300td-color-code-vacuum-tubes-left-side.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-075-300td-vacuum-tubes-center-actuator.jpg  

__________________
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 12:31 AM.
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  #17  
Old 06-17-2006, 11:58 PM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
076 300TD Disconnect plastic tubes to center vent element
077 300TD/240D Uncouple the wire harness at the driver side floor vent
078 300TD/240D Uncouple the wire harness at the drivers side of evap box
079 300TD Remove the ETR sensor
080 300TD Unclip the connector base on the drivers side case


Page 17
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-076-300td-disconnect-red%3Dblue-vacuum.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-077-300td-240d-uncouple-wire-harness-driver-side-floor-vent.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-078-300td-240d-uncouple-wire-bundle-driver-side-case.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-079-300td-removed-etr-sensor.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-080-300td-unclip-socket-base-driver-side-case.jpg  

__________________
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 12:32 AM.
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  #18  
Old 06-17-2006, 11:58 PM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
081 300TD/240D Unbolt and pull out both left and right support straps
082 300TD/240D Unbolt the top bolt of the support straps, note the order
083 300TD/240D Remove the heater core hose form the drivers side and passenger side (shown, see below for drivers side on the 240D))
084 300TD/240D Note the positions of the clamp screws for reinstallation
085 300TD/240D Tape over the heater core tubes to prevent water from dripping while
removing


Page 18
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-081-300td-240d-pull-out-support-strap-underneath-evap-box.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-082-300td-240d-unbolt-left-top-note-support-rod-attached.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-083-300td-remove-heater-core-hoses-passenger-side.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-084-300td-note-clamp-screw-location-all-hoses.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-085-300td-240dtape-tube-prevent-spills-cab-when-removing.jpg  

__________________
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 01:08 AM.
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  #19  
Old 06-17-2006, 11:58 PM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
086 300TD Remove the interior passenger side tube
087 240D Disconnect the drivers side heater hose
088 240D Remove the 2 passenger side heater hoses
089 240D Move the heater hoses up above the vent area to prevent drips
090 Evacuate the Ac system of all freon. Disconnect the Ac hoses at the expansion valve


Page 19
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-086-300td-remove-pax-side-tube.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-087-240d-disconnect-driver-side-heater-hose.-drain-radiator-first.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-088-240d-remove-2-passenger-side-heater-hoses-downstream-heater-control-valve.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-089-240d-move-hoses-above-hood-lip-prevent-dripping.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-090-evacuate-ac-system.-then-disconnect-ac-hoses-expansion-valve..jpg  

__________________
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 12:35 AM.
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  #20  
Old 06-17-2006, 11:59 PM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
091 Unscrew the wire ground on the drivers side of the evap box
092 Unzip the wire bundle lock on the drivers side of the evap box
093 240D Either disconnect the Bowden cables or route all wires out of the bowden
cables way for removal ( Again this panel was broken. You would normall disconnect the bowden cables)
094 240D Pull fiber optic spider from AC control bracket
095 Unbolt the switchover valve from the mount


Page 20
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-091-unscrew-wire-ground-block-drivers-side-heater-box.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-092-unzip-wire-bundle-lock-drivers-side-heater-box.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-093-240d-either-disconnect-bowden-cable-route-all-wires-out-bowden-cable-way.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-094-240d-pull-fiber-optic-spyder-ac-control-bracket.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-095-unbolt-switchover-valve-mount.jpg  

__________________
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 01:10 AM.
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  #21  
Old 06-17-2006, 11:59 PM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
096 Disconnect the vacuum hose from the fresh air element
097 Pull the flex hose from the drivers side and passengers side
098 Detach the wire harness socket from the evap box
099 Passenger side disconnect the fan wire harness
100 Unbolt both mounting strap bolts at transmission tunnel. Do not unhook at the top.
They are difficult to reinstall. Just place aside


Page 21
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-096-disconnect-vacuum-hose-fresh-air-element.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-097-pull-flex-hose-form-driver-side-heater-box.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-098-detach-wire-harness-socket-heater-box.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-099-right-side-unlock-vacuum-wire.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-100-unbolt-mount-strap-lower-bolt-both-sides-trans-tunnel-move.jpg  

__________________
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 12:38 AM.
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  #22  
Old 06-17-2006, 11:59 PM
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
101 Unbolt passenger side top mount nut
102 Unbolt middle section top mount nut
103 Unbolt drivers side top mount nut
104 Unbolt lower mount bolt
105 It is best to completely remove the lower mount bracket so you donít hit the evap
box


Page 22
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-101-unbolt-passengers-side-mount-nut.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-102-unbolt-middle-mount-nut.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-103-unbolt-drivers-side-mount-nut.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-104-unbolt-lower-support-nut.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-t-damage-evap-box.jpg  

__________________
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 12:40 AM.
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  #23  
Old 06-17-2006, 11:59 PM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
106 Remove the passenger side of the box first and pull towards the passenger door
Just like the dash. Watch for water leaking out of the heater core tubes
107 Separating the heater box from the evap box. How to push the tabs
108 Remove the tabs to separate the heater box. This tab and the opposite one on the box
109 Remove the 2 tabs Iím pointing at to separate the heater/evap box
110 Remove the left side heater box bolt. Save all parts


Page 23
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-106-remove-box-passengers-side-first-towards-rear-then-out-passenger-door.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-107-separating-heater-box.-how-push-tabs.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-108-remove-tab-separate-heater-box.-tab-one-oposite-side-heater-box.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-109-remove-2-tabs-pointing-separate-heater-box.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-110-remove-left-side-heater-box-bolt.-save-bolt-nut.jpg  

__________________
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 12:41 AM.
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  #24  
Old 06-18-2006, 12:00 AM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
111 Remove the right side heater box nut. Save all parts. Now separate the heater and
evaporator box sections
112 Separating the fresh air section from the evap section. Remove these 4 clips.
113 Separating the fresh air section. Remove these 2 clips (6 total)
114 Separating the fresh air section. Remove these 2 clips (Now 8 total)
115 Separating the fresh air section. Remove these 4 clips (Now 10 total)



Page 24
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-111-remove-right-side-heater-box-nut.-save-bolt-nut.-separate-heater-box-evaporator-box.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-112-separating-fresh-air-section.-remove-4-clips.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-113-separating-fresh-air-section-.-remove-these-2-clips.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-114-separating-fresh-air-section.-remove-thises-2-clips.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-115-separating-fresh-air-section.-remove-these-4-clips.jpg  

__________________
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 01:13 AM.
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  #25  
Old 06-18-2006, 12:00 AM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
116 Separating the fresh air section. Disconnect the element shaft from the door
117 240D Separating the fresh air section. Either unhook the cable or unclip the cable housing from the mount. This cable operates the "main air flap"
118 240D Separating the fresh air section. Remove the clip that holds the cable
119 Separating the fresh air section. Unplug the fan wire harness
120 Separating the fresh air section. Remove the wire harness from the base mount


Page 25
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-116-seperating-fresh-air-section.-disconnect-element-shaft-door.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-117-240d-only-separating-fresh-air-section.-either-unhook-cable-.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-118-240d-only-separating-fresh-air-section.-removing-clip-holds-cable-sheath.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-119-separating-fresh-air-section.-unplug-fan-wire-harness.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-120-separating-fresh-air-section.-remove-wire-harness-base-mount..jpg  

__________________
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 02:33 PM.
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  #26  
Old 06-18-2006, 12:00 AM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
121 Separating the fresh air section. Unhook the wire harness form the box
122 240D Separating the fresh air section. Remove the blower motor resistor unit from
the evap box
123 Remove and replace the fresh air element while youíre here
124 Separating the evap section. Remove these 3 clips
125 Separating the evap section. Remove these 2 clips (5 total)


Page 26
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-121-separating-fresh-air-section.-unhook-wire-harness-box.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-122-separating-fresh-air-box.-remove-blower-motor-speed-resistor-unit-remove-harness.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-123-remove-replace-fresh-air-element-while-your-here..jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-124-separating-evap-section.-remove-3-clips.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-125-separation-evap-section.-remove-2-clips.jpg  

__________________
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 12:46 AM.
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  #27  
Old 06-18-2006, 12:00 AM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
126 Separating the evap section. Remove the foam and these 3 clips (8 total)
127 Separating the evap section. Slide the upper case off the evaporator
128 Note clearance of expansion valve to evap box. Critical when reassembling unit. You may have to bend the copper tubes of the evap to install the new unit
129 Note the position of the sheetmetal piece and foam. Foam also on the bottom
130 Remove the black tar sealant from around the expansion valve. Note rubber sealing
wall. Remove the rubber wall with the evaporator


Page 27
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-126-separation-evap-section.-remove-foam-then-3-clips.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-127-separte-evap-section.-slide-upper-case-above-evaporator.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-128-note-clearance-expansion-valve-evaporator-box..jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-129-note-position-sheetmetal-piece-foam.-also-foam-under-side-evaporator.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-130-remove-black-tar-sealant-around-evap-tubes.-note-rubber-sealing-wall..jpg  

__________________
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 02:34 PM.
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  #28  
Old 06-18-2006, 12:01 AM
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
131 Note how much dirt is in the fins of the evaporator.
132 300TD "Recirculation air flap" element
133 300TD Heater core tubing
134 300TD Close up. "Recirculation air flap" element
135 300TD Close up. "Main air flap" element


Page 28
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-131-note-how-much-dirt-evaporator.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-132-300td-fresh-air-actuator.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-133-300td-heater-block-tubing.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-134-300td-close-up-fresh-air-actuator.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-135-300td-close-up-fresh-air-element.jpg  

__________________
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 02:36 PM.
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  #29  
Old 06-18-2006, 12:01 AM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
Posts: 2,692
136 300TD "Center nozzle flap" section and element
137 300TD "Defrost nozzle flap" element, located on the drivers side of the evap/heater box.
138 300TD Center section of evap box
139 300TD The upper element is the "Defrost nozzle flap" element. The lower element is the "legroom flap"
140 300TD The expansion valve area.

Page 29
Attached Thumbnails
Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-136-300td-center-vent-element.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-137-300td-driver-side-defroster-element.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-138-300td-center-section.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-139-300td-left-side-evap-box.jpg   Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD)-140-300td-exp-block-center-actuator.jpg  

__________________
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 02:40 PM.
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  #30  
Old 06-18-2006, 12:01 AM
dmorrison's Avatar
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Join Date: Dec 2002
Location: Colleyville, Texas
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Some thoughts on this job.

The first car done, the 300TD, took a while to do. I did a lot and was a little lazy doing the job. The second car, the 240D took 3 days to do. We took lots of pictures and check everything over. I also spent a couple of hours re-gluing the AC control panel unit. I had ordered one and I eventually got it, but my Daughter needed to get back to school. I have it and will probably never install it I probably could have gotten the job done in one long day, but I don't like to work that way.



While your there. Consider replacing the following

All vacuum elements.
All vacuum connections
Of course the evaporator
Possibly the heater core ( this could be fixed with leak stop, I would not do this job JUST for a leaking heater core.)
All light bulbs
Check all the plastic vacuum tubes for damage.
Check the condition of the evaporator box and epoxy any weak areas.
Air temp foam tube, consider replacing it with a hard plastic tube
Evaporator box drain tube. I used a garbage disposal to sink drain adapter tube. ( make sure you install your tube before installing the evap box in the car )
Rebuild the instrument cluster, its out
Check all the vents in the dash for broken tabs where they mount. They use 4 tabs integrated in the vent to hold it in position, these break
Time to really clean up the mess under dash and center console

Here is the post I did that is just a word description of the evaporator installation. It has some lengthly considerations posted. This post along with the one below should be adequate for anyone doing this job.

Order for installing evap box in a W123.

Dave
__________________
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 PM.
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