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Old 06-26-2008, 05:17 AM
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David Selig
 
Join Date: Jun 2008
Location: Harvard, MA
Posts: 44
W124 (124.290) Evaporator, Vacuum Pod, and Bulb Replacements

Here is my step by step version with pics of the evaporator replacement:

1. Notes
___A. I have a 1992 300 TE 4matic. Model 124.290 Engine 103.984.
___B. Sources
______1. Mercedes W 124 Repair Manual
______2. Thread on evaporator My turn for the Evaporator Party
______3. A post on vacuum pods W124 climate control vacuum pod replacement including pictures of pods: http://www.w124performance.com/images/W124___dash/
______4. W123 AC evaporator replacement http://www.peachparts.com/Wikka/W123Evaporator
______5. http://www.peachparts.com/shopforum/diesel-discussion/121523-124-evaporator-core-replacement-help.html#post870494
___C. Steps below in ALL UPPERCASE come from MB Repair Manual on CDROM.
___D. The rest are my addition to the original steps, some of which were derived from other threads on this forum.
___E. All connectors such as screws and nuts were replaced in their original position during disassembly unless a numbered Bag (e.g. Bag3) is noted below. In that case, connector goes in the numbered Ziploc bag and is set aside.
___F. a magnet for retrieving dropped parts is helpful
___G. my system was converted to R134a and I decided to keep it that way for now
2. Parts
___A. R 134a
___B. Nylog blue for R134a system
___C. Vacuum Pump
___D. Initially planned PAG 46 compressor oil / Denso ND8 oil - Q1130001 but since the oil in the current system is unknown, switched to NAPA ester100 oil with dye since it is compatible with PAG and residual mineral oil.
___E. antifreeze
___F. coolant thermostat
___G. Aluminum Mag Wheel Cleaner (acid)
___H. 10” of Tubing Ύ” ID 1” OD for AC drainage
___I. Ace Hardware #51278 Open Cell Rubber tape 3/8” x Ύ”. Need 5 ft
___J. NAPA #MS 4196 Glass Butyl Tape 3/8” x 15’ for sealing heater core to firewall. Need about 5 ft.
___K. liquid nails
___L. Orings set for heater core A1248350498 (EPCNet 124.290 83 060 26) – ended up not using this as could not get pipes off heater core to replace o rings.
___M. AC
______1. ACM Evaporator A1248300758 (EPCNet 124.290 83 060 104) with attached expansion valve A1408300484 (EPCNet 124.290 83 060 107)
______2. Receiver / Dryer A1248300283 (EPCNet 124.290 83 195 47)
______3. Pressure switch A1248213651 (EPCNet 124.290 83 195 65)
______4. Aux fan Temperature switch A0048206810 (EPCNet 124.290 83 195 56)
______5. AC Oring Kit – only used 4 Orings
___N. lights
______1. Nozzle lights and light for illumination of headlight control N000000001061 x 4 (EPCNet 124.290 54 395 158. Also A0008250094) “air nozzle lighting and rotary switch lighting”
______2. Foglamp indicator bulb: A0025440194 (EPCNet 124.290 54 640 11)
______3. Instrument cluster backlight x 2: N072601012240 (EPCNet 124.290 54 585 53) 3W
______4. Gear shift light N072601012230 (EPCNet 124.290 26 075 116) 1.2W
______5. Climate control unit light x 2. Original is 1.2 W so use gear shift light N072601012230 (EPCNet 124.290 26 075 116) 1.2W
______6. ashtray light N072601012110 (EPCNet 124.290 68 270 53) 2W
___O. Vacuum elements
______1. Right main airflap without dust filter A1248001175 (EPCNet 124.290 83 060 152)
______2. Left main airflap without dust filter A1248000475 (EPCNet 124.290 83 060 143)
______3. Defroster airflap A1248002675 (EPCNet 124.290 83 060 125)
______4. Cold Air airflap A1248000375 (EPCNet 124.290 83 060 140)
______5. Control of shutoff airflaps A1248000275 (EPCNet 124.290 83 060 137)
______6. Legroom airflap A1248000975 (EPCNet 124.290 83 195 152)
3. Job 83-554 (C:\Program Files\MB 300 CDROM\Program\Climate\83-554.pdf )
___A. Have Indy Drain AC (per EPA cannot vent)
___B. Adjust seats all the way back and all the way down
___C. Open sunroof for space and point light from there
___D. Open all windows for ventilation while working
___E. Telescope steering wheel
___F. Disconnect battery and remove
___G. Remove cover on computers to give access to right heater core connections (Pic014). Later hooked up automatic battery charger on 2 amp setting and rolled down windows as had forgotten to do this before – don’t know whether this is ok for electrical system.
___H. Remove grill on air inlet 83-040 (I do not have this PDF)
______1. take off water seal along lower edge of windshield – just pry it off with fingers (Pic001). It is attached by pressure joint (Pic002) in 3 places.
______2. take off seals between engine compartment and hood and between air intake cowling and hood (Pic003)
______3. take off 2 screws from each lateral water drain below windshield, remove white clips by pulling forward (Pic004), and remove water drains. I broke both – part #A1246280228.
______4. unscrew sound proofing between engine compartment and air intake – 4 large plastic nuts/screws (Pic005) and pull soundproofing out then down (Pic006)
______5. remove 2 screws holding sides of air intake assembly (Pic007)
______6. remove 4 tiny screws into molding holding edge of semicircular rubber cover next to base of windshield wiper (Pic008). On assembly be sure to get end of circular molding under adjacent molding (Pic009).
______7. remove critical 2 screws holding air intake assembly down (Pic010). Screws are concealed by engine sound proofing. Also note in picture how lines travel between soundproofing and air intake assembly.
______8. Unclip on both sides (Pic011) and lift out air intake assembly (Pic012).
______9. Need to do all this to get good access to remove power for blower motor, and helps access to evaporator connections and Left heater core connection (Pic013) as well as right heater core connections (Pic014)
___I. DRAIN AC – already done by Indy.
___J. DRAIN COOLANT and replace coolant thermostat. Run at 1500 RPM to refill heat exchanger according to another post.
___K. DISCONNECT HOSES TO HEAT EXCHANGER (2 on right side, 1 on the left. Blow out with compressed air or seal to keep from dripping coolant in car (Pic014) R (Pic015) L. Removed seal from R before pulling BOX. (Pic016).Bag6
___L. DISCONNECT AC LINE CLAMP (Pic017) Bag1
___M. REMOVE MOUNT FOR CHECK VALVE - skipped
___N. PULL PIPES OUT OF EXPANSION VALVE BY LOOSENING NUT. This step delayed until ready to pull BOX (Pic018) Bag7. Had to use 10 mm ignition wrench. Cap the ends with plugs – used those from MityVac. Close R134a filled system fast as compressor oil absorbs moisture However have also read that drawing vacuum pulls moisture back out of oil. During reassembly use new gaskets on AC evaporator fittings and coat with Nylog. My old O rings were black so no O ring swap was done with conversion by dealership. Fill evaporator with 40 ml compressor oil 83-525 (C:\Program Files\MB 300 CDROM\Program\Climate\83-525.pdf ).

(continued in next post)
__________________
1991 300TE 4matic 205k miles (bought 2000)
1992 300TE 4matic 200k miles (bought 2000)
1992 300TE 4matic 150k miles (bought 2004)

Last edited by BoxfordBenz; 06-26-2008 at 01:08 PM.
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  #2  
Old 06-26-2008, 05:23 AM
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David Selig
 
Join Date: Jun 2008
Location: Harvard, MA
Posts: 44
W124 (124.290) Evaporator, Vacuum Pod, and Bulb Replacements (continuation 1)

___O. PULL BLOWER MOTOR CONTROLLER LEAD (Pic019) and pull grommet and lead into air intake (Pic020).
___P. Remove floor mats after skipping forward and removing left covering panel under instrument panel (step Q.4.a below) and center console (step R below). I had difficulty releasing the left floor mat with the center console in place due to plastic stiffening insert (Pic059)
______1. left
_________a. remove plate at right front base of seat (Pic060)
_________b. unscrew anchor of floor mat to center console (Pic061) Bag3.
_________c. pulled floor mat from lower door molding (Pic062)
_________d. pulled floor mat from around left lower air outlet (Pic063)
_________e. released gas pedal at base (Pic064)
____________i. propped up floor mat with boards (Pic065)
____________ii. released clip for gas pedal at base under left floor mat from the front of car while pulling rearward with pliars (Pic066) (some helpful diagrams in 30-0012 [C:\Program Files\MB 300 CDROM\Program\Engine\104\30-0012.pdf ])
_________f. reglue foam padding to carpet using liquid nails. Also reglue plastic stiffner near center console to carpet with liquid nails (Pic059).
______2. right
_________a. remove plate at left front base of passenger seat (Pic067)
_________b. lift floor mat up and toward center of car
_________c. reglue plastic stiffner near center console to carpet with liquid nails (see Pic059).
___Q. REMOVE INSTRUMENT PANEL (dashboard) 68-100 (C:\Program Files\MB 300 CDROM\Program\Chassis\68-100.pdf)
______1. REMOVE AIRBAG 91-660 AND STEERING WHEEL 46-8240 – skipped. Just telescoped steering wheel and had no problems. If removing, be sure and disconnect electric airbag connector under right footrest first. Also unlock steering so that do not shear locking mechanism while loosing nut on steering wheel.
______2. REMOVE LOUDSPEAKER COVERS 68-105 (C:\Program Files\MB 300 CDROM\Program\Chassis\68-105.pdf) & http://www.peachparts.com/Wikka/W124Stereo
_________a. UNCLIP COVERSTRIP AND REMOVE (Pic068 Pic069)
_________b. REMOVE SCREWS (Pic070) AND TAKE OFF COVER IN INWARD DIRECTION
______3. REMOVE INSTRUMENT CLUSTER 54-6015 (C:\Program Files\MB 300 CDROM\Program\Chassis\54-6015.pdf ) & http://www.peachparts.com/Wikka/W124InstCluster
_________a. DISCONNECT BATTERY (done already)
_________b. DETACH SPEEDOMETER SHAFT AT TRANSMISSION. 54-5600 is somewhat helpful in showing how to do this (C:\Program Files\MB 300 CDROM\Program\Chassis\54-5600.pdf ) however I skipped this step.
_________c. UNCLIP SPEEDOMETER SHAFT AT FRONT COVER OVER PEDALS FROM RETAINING CLIP.
_________d. PULL OUT INSTRUMENT CLUSTER WITH WITHDRAWING HOOK. INSTRUMENT CLUSTER HELD IN PLACE BY 5 SPRING CLIPS. Instead of this approach, I used bar at the right side and fingers at left to pull out instrument cluster (Pic071 Pic072) As I eased it out, I, pulled speedometer cable through from below so that there was no tension.
_________e. UNSCREW SPEEDOMETER SHAFT AT INSTRUMENT CLUSTER. Come from R side as all electrical connections come in from L (Pic073).
_________f. DISCONNECT ALL ELECTRICAL CONNECTIONS (Pic074 Pic075 Pic076). Release clip on back of instrument cluster (Pic077) and placed cable tie on cables. Note that instrument cluster must be electrically connected during reinstallation in order to test all lamps that were replaced since their intensity is controlled by the knob in instrument cluster.
_________g. PULL OUT INSTRUMENT CLUSTER
______4. REMOVE LEFT AND RIGHT COVERING PANELS UNDER INSTRUMENT PANEL (dashboard) 68-150 (C:\Program Files\MB 300 CDROM\Program\Chassis\68-150.pdf )
_________a. LEFT COVERING PANEL UNDER INSTRUMENT PANEL
____________i. REMOVE FLOOR MAT. Skipped as not necessary hered
____________ii. unclip speedometer cable from lower left panel near steering column.
____________iii. UNSCREW AND REMOVE BLACK COVER ABOVE PEDAL (left lower panel)– Take out 2 screws and a plastic nut (Pic021 Pic022 Pic023). Easier perhaps to do this after left panel is taken off. During reinsertion, put right corner of cover behind left lower air outlet (Pic024) and get left side above left side molding (Pic025)
____________iv. Remove 2 lower screws on left panel (Pic026)
____________v. DISCONNECT ENGINE HOOD CABLE FROM HANDLE (Pic027) and remove handle in order to be able to drop left panel
____________vi. REMOVE HEADLIGHT KNOB by pulling straight out.
____________vii. REMOVE NUT AND SLIP MOLDING IN OUTWARD DIRECTION (Pic028 Pic029). Replace bulb for fog lights indicator. Note that molding centered over steering column will release as well. Leave it all dangling. It is hard to take off center molding alone without damaging it.
____________viii. PULL OFF MOLDING FOR BEAM RANGE REGULATOR AND SWITCH LIGHT and remove lamp socket with lamp (Pic030). Replace bulb with 0.4W. Be certain to place back in slot before replacing cover.
____________ix. REMOVE MOLDING FROM IGNITION LOCK (Pic031). It will come off with center molding.
____________x. REMOVE 2 SCREWS TO RIGHT OF TO IGNITION (Pic032)
____________xi. REMOVE 3 SCREWS TO LEFT OF STEERING COLUMN (Pic033)
____________xii. DISCONNECT CABLE CONTROL FOR PARKING BRAKE AT HANDLE AND REMOVE HANDLE (Pic034)
____________xiii. REMOVE LEFT PANEL. Next time should take lower left panel and left panel off as a unit and especially put on as a unit. Putting lower left panel on last is quite difficult and doing them together should alleviate some problems.

(continued in next post)
__________________
1991 300TE 4matic 205k miles (bought 2000)
1992 300TE 4matic 200k miles (bought 2000)
1992 300TE 4matic 150k miles (bought 2004)

Last edited by BoxfordBenz; 06-26-2008 at 12:53 PM.
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  #3  
Old 06-26-2008, 05:26 AM
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David Selig
 
Join Date: Jun 2008
Location: Harvard, MA
Posts: 44
W124 (124.290) Evaporator, Vacuum Pod, and Bulb Replacements (continuation 2)

_________b. RIGHT SIDE
____________i. REMOVE GLOVE BOX (not my car) OR PASSENGER AIR BAG
_______________(1). GLOVE BOX
__________________(a). UNSCREW BOTH SCREWS ON SHACKLE
__________________(b). PUSH OUT GLOVEBOX LIGHT AND EXPANDING RIVETS
__________________(c). remove screws at bottom of glovebox?
__________________(d). PULL TOP OF GLOVE BOX DOWN ABOUT 1CM AND PULL OUT
__________________(e). REMOVE SCREWS AND TAKE OFF GLOVE BOX COVER
_______________(2). AIRBAG REMOVAL 91-680 (C:\Program Files\MB 300 CDROM\Program\Chassis\91-680.pdf )
__________________(a). TURN OFF IGNITION
__________________(b). DISCONNECT NEGATIVE TERMINAL OF BATTERY
__________________(c). REMOVE FLOOR MAT AND FOOT REST ON PASSENGER SIDE (Pic078) – already out
__________________(d). DISCONNECT RED TEST COUPLING FOR AIRBAG PLUG CONNECTION x29/9 (Pic079)
__________________(e). UNSCREW AND REMOVE CENTRAL RETAINING BOLT FOR PASSENGER AIRBAG UNIT (Pic080) Bag3
__________________(f). DISCONNECT PLUG X 2 AND WITHDRAW PASSENGER AIRBAG UNIT (Pic081). WHEN RECONNECTING THERE MUST BE A CLICK AND THE SRS WARNING LAMP MUST GO OUT AFTER 4 SECONDS. Reattach clip to back of airbag unit when installing to help prevent accidental disconnection.
__________________(g). STORE AIRBAG CUSHION SIDE UPPERMOST. IF DROPPED FROM MORE THE 50 CM MUST NOT REUSE.
__________________(h). BEFORE REINSTALLING MAKE SURE BATTERY DISCONNECTED, IGNITION KEY AT 0 POSITION, TEST COUPLING x29/9 DISCONNECTED
____________ii. PULL RIGHT AIR NOZZLE. There are four little metal spring clips that hold the vents in place. You gently pry up with a tiny screwdriver while wiggling the vent forward. It comes out a little bit at a time. Can fix metal clips on AC vents with JB weld however I used gorilla glue. Remove light socket from flap control and replace bulb with 0.4 W (Pic082 Pic083)
____________iii. REMOVE 2 SCREWS FROM AIR NOZZLE CUTOUT (Pic084)
____________iv. remove 4 screws around glovebox on R and 4 on L (Pic085 Pic086). Note that front 2 screws on both sides go into bracket that is behind covers (Pic087) Bag3.
____________v. REMOVE 3 SCREWS BELOW DASHBOARD (Pic088). Remove lower part of right lower cover (Pic089). Note that lower right cover tucks into several different slots.
____________vi. REMOVE RIGHT LOWER COVER TOWARD REAR
____________vii. DURING INSERTION, MAKE SURE COVER IS IN RIGHT UPPER OUTER CLAMP.
______5. REMOVE LEFT AND RIGHT REVEAL MOLDINGS 68-405 (C:\Program Files\MB 300 CDROM\Program\Chassis\68-405.pdf )
_________a. PULL OFF CHAFE STRIP IN RANGE OF REVEAL MOLDING (Pic090)
_________b. POSITION PLASTIC WEDGE ON CLIPS AND KNOCK AGAIN WEDGE WITH BALL OF THUMB. Just popped this off with my hands. There are two clips holding (Pic091) it in place.
_________c. SLIP REVEAL MOLDING OUT OF ROOF FRAME TRIM AND REMOVE. Pull straight back since 2 more clips (Pic092) found toward front of molding.
_________d. When reassembling, put 2 front clips in each molding before attaching to car (Pic160).
______6. Remove headlight switch from instrument panel (Pic094)
______7. UNSCREW NUT ON LEFT SIDE and slip out of slot (Pic093)
______8. TAKE OUT SCREW IN THE LEFT AND RIGHT LOUDSPEAKER CUTOUT as this bolts dashboard to car (Pic095) Bag4.
______9. PULL OUT AIR NOZZLE ON LEFT SIDE. Remove light from flap control (Pic096) and replace bulb with 0.4 W. Glue metal clips back in place. See notes about R nozzle.
______10. WITH LOUDSPEAKER INSTALLED, SEPARATE CONNECTING CABLE AT PLUG COUPLING. Took this to mean disconnect connector to speaker on each side (Pic097). There is a 2nd connector on R which is probably to tweeter vs car phone speaker (Pic098).
______11. RELEASE ADJUSTING SCREW ON CONNECTING LINKAGE OF FRESH AIR FLAP USING 4MM HEX KEY at center air nozzle (Pic099). Note screw is held in place so you will not loose it. Adjust it during reassembly.
______12. Remove screw on right side of center nozzle (Pic100) Bag5
______13. Remove center nozzle by releasing 2 metal spring clips on L and pulling outward. See notes on R nozzle.
______14. Remove light from center nozzle by releasing 2 tabs on flap at bottom (Pic101). To get lamp out pry one side out then pull – take a look at left and right nozzle light sockets to get the idea as socket is the same. Replaced bulb with 0.4W even though original has 1.2W printed on it. Note routing of wire (Pic102) for reassembly.
______15. SLIP INSTRUMENT PANEL (DASHBOARD) FROM RIGHT INTO LEFT HAND CORNER ON FRONT WALL PILLAR. Note that instrument panel (dashboard) separates from BOX at defroster joint (Pic103). The defrost vents are attached to the dashboard. During reinsertion, align and insert defrost vents from instrument panel into BOX first to get the whole instrument panel to drop into place. Instrument panel (dashboard) may be glued to windshield if new windshield was installed. Remove center console before pulling instrument panel (dashboard) as two bolts from instrument panel (dashboard) stick down and may damage center console otherwise. I encountered no problem clearing the extended steering wheel. I did have to remove some clips on R reveal molding to make space for instrument panel removal - it was tight. Before reinserting I trimmed the left and right front corners by about Ό”. This helped with insertion and was covered by reveal molding. The view after removal is in this picture (Pic104)

(continued in next post)
__________________
1991 300TE 4matic 205k miles (bought 2000)
1992 300TE 4matic 200k miles (bought 2000)
1992 300TE 4matic 150k miles (bought 2004)

Last edited by BoxfordBenz; 06-26-2008 at 12:56 PM.
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  #4  
Old 06-26-2008, 05:28 AM
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David Selig
 
Join Date: Jun 2008
Location: Harvard, MA
Posts: 44
W124 (124.290) Evaporator, Vacuum Pod, and Bulb Replacements (continuation 3)

___R. REMOVE CENTER CONSOLE 68-200 (C:\Program Files\MB 300 CDROM\Program\Chassis\68-200.pdf )
______1. REMOVE BOTH FLOOR MATS AND FOAM PARTS – skipped as not necessary
______2. REMOVE WOODEN COVER ON SHIFT LEVER 68-230 (C:\Program Files\MB 300 CDROM\Program\Chassis\68-230.pdf )
_________a. remove 2 screws in center console compartment and lift out (Pic035)
_________b. REMOVE SCREW AT REAR BASE OF WOODEN COVER (Pic036)
_________c. pry up and remove molding around shift lever cover (Pic037)
_________d. LIFT COVER FORM REAR TO FRONT. Doesn’t matter whether switches come with cover or not. However may be able to loosen cover by pushing switches down and out of cover (Pic038). Label as L/R then remove seat heater plugs if you have them (Pic039).
______3. renew bulb at shift lever (Pic040)
______4. REMOVE SWITCH FOR BLOWER – not on my car
______5. REMOVE SCREWS AND PULL OFF WOODEN PLATE COVERING CLIMATE CONTROL (Pic041 Pic042) Bag2
______6. remove 6 screws and pull out climate control (Pic043 Pic044). Label L/R then remove plugs for climate control (Pic045)
______7. Replace bulb in climate control unit. 83-635 (C:\Program Files\MB 300 CDROM\Program\Climate\83-635.pdf ). Use 5mm diameter conduit to remove old ones (Pic046). Labeled as 1.2W.
______8. PULL OFF SWITCH FOR BACK WINDOW HEATER. Actually pull off rightmost switch face (Pic047).
______9. release carrier first (Pic048 - switch but not socket should actually be out unlike this picture) then push switch carrier in forward and to right and pull left out (Pic049)
______10. UNSCREW 2 NUTS FROM CENTER CONSOLE TO INSTRUMENT PANEL (DASHBOARD) (Pic050) Bag2
______11. REMOVE RADIO 82-7502 (C:\Program Files\MB 300 CDROM\Program\Chassis\82-7502.pdf )
_________a. remove ashtray (Pic051)
_________b. remove ashtray carrier and detach plug for ashtray light (Pic052). Renew bulb
_________c. PUSH DOWN 2 CLAMPING LEVERS (Pic053)
_________d. INSERT REMOVAL PLATES – not functional in carrier used in this car
_________e. WITHDRAW RADIO and pull 5 plugs (Pic054)
______12. PUSH BACK DETENT AND TAKE SWITCH PLATE OUT OF HOLDER. This just means free window switch plate (Pic055)
______13. UNSCREW REAR FASTENING SCREW (Pic056)
______14. remove 2 screws just to rear of shift lever (Pic057)
______15. UNSCREW FRONT LEFT AND RIGHT FASTENING SCREWS – not on this car
______16. DISENGAGE LOWER HOLDING LINK OF LATERAL TUNNEL LINING – not on this car
______17. DISENGAGE UPPER HOLDING LINK OF LATERAL TUNNEL LINING – not on this car
______18. REMOVE LATERAL LINING TOWARDS REAR (Pic058)
___S. REMOVE AIRDUCTS FOR REAR COMPARTMENT VENTILATION FROM BOX. Remove screw on R (Pic105). Rotate R airduct out of R rear duct (thumb in Pic106). Pull down from BOX. Repeat on L with more wiggling than on R.
___T. REMOVE HORIZONTAL CROSSMEMBER AND VERTICAL BRACE. First remove temperature sensor wire B10/2 or B10/3 (below) as it gets tension when brace comes off. Brace releases with 2 screws (Pic107 Pic108). Brace left hanging in car with wires attached. To remove crossmember, take off 4 screws on L (finger pointing in Pic107). Remove bracket on L (Pic109) by first rotating ignition switch (see instructions 2 steps ahead). Remove 2 nuts on R and pull aspirator blower for interior air temperature sensor from bracket (Pic110). Remove brake cable to shift lever cable (Pic111) and pull out crossmember.
___U. REMOVE 2 BOLTS AND BRACKET HOLDING BOTTOM OF BOX (Pic112) as well as connector next to it (Pic113) Bag6
___V. PULL OUT IGNITION LOCK BY UNLOCKING WITH KEY (POSITION 1), TURNING SCREW (Pic114), PRESSING IN RETAINING PIN (Pic115), and rotating. TO GET IT OUT REALLY NEED TO BEND IT DOWN AND TOWARD REAR OF CAR (Pic116).
___W. REMOVE HEAT EXCHANGER TEMPERATURE SENSOR CONNECTOR ON BOX B10/2 AND B10/3. I only found one and part of it broke off (Pic117). REMOVE CONNECTOR TO EVAPORATOR TEMPERATURE SENSOR B10/6 (Pic118). Remove wiring for B10/6 from bracket by elevating clip (Pic119) and pulling out.
___X. REMOVE VACUUM LINES, 2 POLE CONNECTOR, AND SWITCHOVER VALVE Y13/1. Skipped. Just remove vacuum line coming from engine compartment (Pic120) and release from 2 clips on back of BOX. Also pull control plug to switchover valve (Pic121).
___Y. remove bracket to left and above BOX holding various electronics (perhaps including seatbelt warning light relay - Pic122)
___Z. REMOVE LEFT AND RIGHT AIR DUCTS FOR NOZZLES (Pic122). Left must be pulled out a fair bit so that expansion valve on evaporator has clearance during removal.
___AA. PULL OUTSIDE AIR TEMPERATURE SENSOR B10/5 FROM HOLDER (Pic124)
___BB. Remove cable tie attaching wires to lower left of BOX near lower left bolt (Pic125) and place new cable tie. Reattach when reinstalling.
___CC. remove clips and drains for evaporator from both sides of BOX at bottom (Pic126) and discard. Clean old tubing out of hole once evaporator is off and replace on both sides with with Ύ” ID x 5” length tubing from Lowes. Clips not used Stretched out one end of tube before putting on with vicegrips.

(continued in next post)
__________________
1991 300TE 4matic 205k miles (bought 2000)
1992 300TE 4matic 200k miles (bought 2000)
1992 300TE 4matic 150k miles (bought 2004)

Last edited by BoxfordBenz; 06-26-2008 at 12:57 PM.
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Old 06-26-2008, 05:34 AM
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David Selig
 
Join Date: Jun 2008
Location: Harvard, MA
Posts: 44
W124 (124.290) Evaporator, Vacuum Pod, and Bulb Replacements (continuation 4)

___DD. Actually did step O (pulling pipes out of expansion valve) at this point so as not to leave AC open for (albeit plugged) for as long..
___EE. UNSCREW 4 NUTS (Pic122 Pic125 Pic127 Pic128) Bag7 AND PULL BOX DOWN AND OUT (needed pry bar to get BOX from firewall on Upper and Lower R and Lower L. Could not fit in upper Left so used vise grips to pull that side. Had to wiggle it out, pulling hard. Took 5-10 minutes.) Picture of firewall with BOX out (Pic129). Note large wire across top of opening that has to be lifted in order to pull out and to reinsert BOX.
___FF. Replace gasket in bulkhead. Scraped off old with slotted screwdriver. Used Ace Hardware #51278 Open Cell Rubber tape 3/8” x Ύ”. Worked well
___GG. REMOVE OLD SEALANT AND APPLY NEW TO BOX. Used NAPA #MS 4196 Glass Butyl Tape 3/8” x 15.
___HH. OPENING HEATER / AC BOX
______1. Disconnect all vacuum element lines (Pic130) noting color coding
______2. REMOVE 10 CLIPS ON FRONT (Pic131) Bag7
______3. UNSCREW 4 SCREWS ON TOP AND REMOVE COVER (Pic132) Bag7
______4. Remove Heat exchanger 83-522 (C:\Program Files\MB 300 CDROM\Program\Climate\83-522.pdf )
_________a. RELEASE MAIN AIR FLAP VACUUM ELEMENTS by removing 3 screws (Pic133) and releasing vacuum element from metal bar. I made mistake of removing bar from actuators and broke several connections. To repair drilled hole and tied bar to actuator with upholstery thread to keep them from separating (Pic134).
_________b. REMOVE BOX COVER – already done
_________c. REMOVE CLIP FOR COOLANT LINE ON EITHER SIDE (Pic135) by slipping screw driver between clip and box in 2 places for each clip
_________d. LIFT HEAT EXCHANGER (Pic136)
_________e. tried to replace 3 o ring seals but could not get upper 2 pipes off. Gave up.
______5. Remove linkage for legroom vacuum element (Pic137)
______6. Remove linkage from left side (via bottom) for left and right legroom airflap (Pic138). Linkage broke on R later. Sewed it together with upholstery thread rather than waiting several days to get part (Pic139). Amazing that it lasted this many years. On reassembly, adjust linkage so both sides open and close at same time.
______7. Remove 2 screws each on left and right of box and remove front upper housing on each side (Pic140) Bag8
______8. Remove vacuum connection to center vacuum element on upper front box (Pic141)
______9. UNCLIP 4 CLIPS EACH ON L AND R OF BOX IN FRONT OF BLOWER MOTOR HOUSING (Pic142 Pic143) Bag7
______10. UNCLIP 3 CLAMPS EACH ON L AND R AND 1 CLAMP IN CENTER OF BOX (in picture 3rd clamp is above the 2 being pointed at Pic144 Pic145) Bag7
______11. PRESS OUT CLIP (Pic146)
______12. TAKE OUT EVAPORATOR. Note the crud in fins (Pic147). This was already vacuumed out a few months ago which is why I suspected a evaporator leak. Also decided to suck off all the friable foam from the outside of the recirculation flap as this may be been flaking off and getting stuck in evaporator (Pic148 Pic149). Inside foam was not nearly so friable.
______13. Remove molding around evaporator inlet and outlet (Pic150) When replacing, added sealant to molding as there was a large gap – used removable sealant from ACE Hardware: red devil zip away removable weather stripping. Could have used another sealant. Also placed same sealant at firewall where evaporator inlet and outlet pass through gasket (Pic159).
______14. MOVE SCREEN FROM OLD (Pic150) TO NEW EVAPORATOR AND INSERT. For ACM evaporator pipes had to be bent slightly to get them to come out of BOX correctly. Also note that during reassembly tabs (Pic154) on upper front of evaporator must be centered in box or cover will not go on properly. I had to slide evaporator to one side for this to happen.
______15. clean fins of heater core if necessary – it was not
______16. Replace all vacuum pods 83-665 (C:\Program Files\MB 300 CDROM\Program\Climate\83-665.pdf ) Only pods that did not work controlled recirculation. Hints below apply if BOX was not taken out of car. For all pods, remove at hub of pod rather then at distal end of steel actuator.
_________a. REPLACE DEFROSTER POD TO RIGHT OF BOX (Pic151). Consider working on R diverter pod while defroster pod is out if working in car.
_________b. REPLACE FOOTWELL POD ON FRONT OF BOX (Pic137)
_________c. REPLACE CENTER POD WITHIN BOX (Pic141). This pod may be replaced without removing heater core. Remove the white pin in the top door. Remove the door by flexing it out of it's hinges. Remove the flat metal rod from the pod. Pull the hose and twist the pod out, it will *just* wiggle out from under the mounting bracket
_________d. REPLACE DIVERTER POD ON BOX COVER (Pic152). The diverter pod is held in by 3 round metal press clips (Pic153), so you need to break out the old one and save the mounting clips for the new pod. To press the washers back onto the new pod, a small 1/4" drive socket works well.
_________e. REPLACE RECIRCULATION POD X 2 BEHIND AND ON EITHER SIDE OF BOX AND ADJUST (Pic133). Leave flat metal bar attached to car for recirc pod. There is a lock tab that must be pressed before the pod will rotate out. Or removal of the bracket holding the seatbelt warning relay to the left of the left recirc pod will make removing the pod easier. Also removal of the defroster pod makes it easier to remove the right recirc pod.
______17. REVERSE ASSEMBLY OF BOX but before installation verify action of vacuum pods 83-620 (C:\Program Files\MB 300 CDROM\Program\Climate\83-620.pdf )
___II. Replace receiver dryer and pressure switch and seal with Nylog 83-540 (C:\Program Files\MB 300 CDROM\Program\Climate\83-540.pdf )
______1. remove air intake cowling to provide space (Pic155)
______2. REMOVE PLUG FROM BOTH PRESSURE SWITCHES (Pic156)
______3. UNSCREW BOTH PRESSURE SWITCHES – not done as using new.
______4. REMOVE BOTH LINES TO FLUID RESERVOIR (Pic157). WHEN TIGHTENING, USE 15-18 Nm.
______5. REMOVE BOTH BOLTS HOLDING RESERVOIR IN PLACE (Pic158)
______6. Replace O rings and LUBRICATE O RINGS AND ALL THREADS WITH COMPRESSOR OIL WHEN REPLACING. Used Nylog instead.
______7. ADD 10 ML COMPRESSOR OIL FOR DRYER AND 10 ML OIL FOR LEAK TO NEW DRYER BEFORE INSTALLATION. 83-525 (C:\Program Files\MB 300 CDROM\Program\Climate\83-525.pdf ).
______8. Better to attach lines and start threads before inserting bolts holding reservoir in place.
___JJ. REASSEMBLE.
___KK. Remove black paint from condenser with acid mag wheel cleaner. May get 20% improvement in cooling. I tried one application but paint did not come off so I moved on.
___LL. PULL VACUUM THEN REFILL AC.


Pic001 to Pic005
Attached Thumbnails
W124 (124.290) Evaporator, Vacuum Pod, and Bulb Replacements-pic001.jpg   W124 (124.290) Evaporator, Vacuum Pod, and Bulb Replacements-pic002.jpg   W124 (124.290) Evaporator, Vacuum Pod, and Bulb Replacements-pic003.jpg   W124 (124.290) Evaporator, Vacuum Pod, and Bulb Replacements-pic004.jpg   W124 (124.290) Evaporator, Vacuum Pod, and Bulb Replacements-pic005.jpg  


Last edited by BoxfordBenz; 06-26-2008 at 01:00 PM.
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Old 06-26-2008, 05:49 AM
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Old 06-26-2008, 06:26 AM
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Old 06-26-2008, 06:30 AM
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Old 06-26-2008, 06:33 AM
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Old 06-26-2008, 06:35 AM
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Old 06-26-2008, 06:37 AM
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Old 06-26-2008, 06:39 AM
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Last edited by BoxfordBenz; 06-26-2008 at 08:47 AM.
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Old 06-26-2008, 06:40 AM
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Old 06-26-2008, 06:42 AM
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Old 06-26-2008, 06:44 AM
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