1977 240D gets a new AC system - PeachParts Mercedes-Benz Forum

resago2000 · #1 08-11-2020, 10:58 AM

So I currently have a York compressor and all the original equipment.

I bought a sanden508 and adapter to mount it.
I have hose, #10 and #8 beadlock fittings and a compression tool.
I have a 12" 90W pusher fan.

I ordered a 16x21 condenser and universal dryer

I need to order #6 line to go from the condenser to the drier and fittings.

I intend to use the existing hose from the dryer to the cabin, but do I need a size adapter? it that line #5?
--So I finally found specs on the dryer/line. it says 3/8 fitting which should be #6, so I'm fine, right?

What else do I need?

I intend to get a new high/low switch to put on the dryer and do the wiring, hooking up the compressor wire to a relay that will power the compressor and fan at the same time.

I will be flushing and drawing vacuum, then filling with R152a.

I want to replace the TXV also, how hard is it to get to and replace?

Thanks for your time.

resago2000 · #2 08-11-2020, 09:57 PM

I will post pics from beginning to end once I get started in the next week or so.

resago2000 · #3 08-12-2020, 02:39 PM

Starting to remove components.
1) removed fan
- 2 bolts on the sides on fan.
- remove 2 phillips head screws holding the bottom rubber trim.
- remove 3rd bolt holding the fan.
- I just cut the wires.
- I took the bolt out of the right brace bar and swung it over a bit to get more room.

2) Remove rotolocks from top of compressor

3)I'm build new hose sections, so I cut the #8 and #10 hoses.

resago2000 · #4 08-12-2020, 02:47 PM

1) Current dryer will be replaced with a new universal one and a new high/low switch.
Green wires go to the compressor. Brown wires run the fan. brown wires will be bypassed and the fan will run when the compressor is engaged.

2) connections to the condenser that need to be removed.

resago2000 · #5 08-12-2020, 02:56 PM

1) IN connection to the condenser apart.
- I ended up cutting the #6 reduced barrier hose to the dryer as it will be replaced anyway.

2-4) Remove clips holding the radiator. If you have the original mechanical fan, take it off so you have clearance. I have an electric fan, so I just tilted my radiator forward.
remove the 4 screws holding the condenser in place. I had to bend the mounting clips to be able to pull it out. Not going to reuse it.
you could always re bend the clips if you wanted to though.

resago2000 · #6 08-12-2020, 03:00 PM

CAREFULLY removed the condenser.

resago2000 · #7 08-12-2020, 03:22 PM

Drier is out.
Loosened and disconnected the #6 line that goes to the cabin. this will be flushed and reused.

resago2000 · #8 08-12-2020, 03:24 PM

Pics of the new sanden508, hoses,fittings, and mounting bracket.

resago2000 · #9 08-12-2020, 03:25 PM

its hot as hell outside, so I'm done for today.

resago2000 · #10 08-12-2020, 03:29 PM

removal of all those pieces took about an hour I guess.
Removing the York compressor is going to be a bear. not sure how I will get to the lower bolts!
maybe have to resort to a sawzall.

pj67coll · #11 08-12-2020, 05:01 PM

Is that your cars original engine?

- Peter.

resago2000 · #12 08-12-2020, 06:32 PM

nope, replaced at some time with a 76 or 75.
no idea when,why,or how that happened, but the engine runs great. no smoke, and smoooooooth.

resago2000 · #13 08-15-2020, 10:08 PM

I got the compressor off. Its a real PITA.

3 bolts removed with a 14mm wrench, side top front, and two on the bottom.
The remaining 3 on the side were cut with my 20v Porter Cable reciprocating saw.
I wouldn't say they it made quick work of it, but it got the job done.
I had to take off the coolant neck on the block to do this.

I guess the correct way to do this is remove the gorilla bracket, them remove the compressor, but that would have been a HUGE pain!!

I will post pictures tomorrow.

after looking at my York compressor, it appears over-filled with oil. I have no idea what the previous owners had done. So my advice would be to others, is if your compress is stalling or slugging, purge the refrigerant and then check the level of oil in the compressor by removing the oil fill bolt, and let any excess oil drain, then vacuum and refill to see if the problem goes away.
My plans for the York compressor are to make an air compressor out of it.

resago2000 · #14 08-16-2020, 03:13 PM

old compressor out, new Sanden in

I used the old washers on the backside of the mounting bolts, use a couple per bolt, or the bolt will extend too far out and interfere with the compressor mount bolts.
Once you have the adapter plate securely mounted, Put the bottom compressor mount bolts in first, then the top.you can't access the bottom bolts easily once the top bolts are in and the compressor is swung into place.

resago2000 · #15 08-16-2020, 03:16 PM

waiting for fittings.