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LinkBack | Thread Tools | Display Modes |
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#16
06-17-2006, 11:57 PM
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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
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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
06-17-2006, 11:58 PM
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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
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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
06-17-2006, 11:58 PM
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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
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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
06-17-2006, 11:58 PM
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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
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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
06-17-2006, 11:59 PM
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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
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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
06-17-2006, 11:59 PM
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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
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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
06-17-2006, 11:59 PM
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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 don’t hit the evap box Page 22
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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
06-17-2006, 11:59 PM
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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 I’m pointing at to separate the heater/evap box 110 Remove the left side heater box bolt. Save all parts Page 23
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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
06-18-2006, 12:00 AM
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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
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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
06-18-2006, 12:00 AM
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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
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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
06-18-2006, 12:00 AM
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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 you’re here 124 Separating the evap section. Remove these 3 clips 125 Separating the evap section. Remove these 2 clips (5 total) Page 26
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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
06-18-2006, 12:00 AM
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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
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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
06-18-2006, 12:01 AM
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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
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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
06-18-2006, 12:01 AM
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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
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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
06-18-2006, 12:01 AM
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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
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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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