190E 2.6 AC/cooling upgrade- Parallel flow W202 condenser install
 

I had been interested in attempting this mod for a while after noticing the similarities between the W201 and W202 condensers. The connections are in similar places but the condenser if slightly wider and much taller.


http://i.imgur.com/LRKmGLO.jpg?1

I was able to test fit one at the yard so I ordered a Valeo unit off of Amazon for $87. I then pulled the aux fan assembly out of a 1st gen CLK from the yard (W202 is the same but all of them were already pulled). Since I am taking classes, most of the work was done by my friend but I can describe the process and point out things that I would have done differently.

Using the mounting brackets from the W202 fans, I mocked up the 201 fan brackets.

https://i.imgur.com/AD5M5HD.jpg

Holes need to be drilled on the 201 fan brackets to fit the 202 mounting brackets, plus maybe some grinding away of material. Again, my friend did this so I'm not entirely sure how it was accomplished but should be fairly straight forward.

https://i.imgur.com/DkrZRQN.jpg

The hose connections come out to about the same point as on the stock condenser. The #12(? larger) line can be reused. the #8(? smaller) must be replaced.

https://i.imgur.com/R3VAJE2.jpg

https://i.imgur.com/lsdO2oq.jpg

Depending on what fittings you have available, you can do a direct run down from the receiver drier to the #8 fitting but he didn't have that available and made a longer hose. These crimp tools are great.

https://i.imgur.com/bTpotka.jpg

Both sides are the same, he secured the condenser to the radiator with zip ties on the bottom. Ideally, we'd make brackets but for my mom's car, cosmetics didn't matter as much.

I don't have pictures of the top be holes were drilled in both the condenser and radiator to bolt them together. Ideally, we'd use brackets.

The stock condenser is designed to sit in between the tanks of the radiator, but since this one is wider, it sits outside of the radiator. That causes some clearance issues but provides a cooling benefit for both the radiator and the condenser by not having metal on metal heat transfer. This is how most modern cooling systems are done anyway.

https://i.imgur.com/gwU7gqg.jpg

Great thing able this mod is it makes servicing the AC so much easier. On the 2.6, the high side port is buried under the intake manifold. Now it's on the side of the condenser.

https://i.imgur.com/03owqOj.jpg

With this condenser and a new AC compressor (clutch was failing on original one after 215K) the pressures are much better running R134 than before and compared to my 190E. AC is much colder than my 190E which we also just serviced.

https://i.imgur.com/3QEe31a.jpg

Decided to put the fan covers back on, they had to be cut to fit. I would have put a spacer between the two fan brackets as the original 201 mounting bracket has so the covers would only need to be cut on the bottom.

https://i.imgur.com/jGQ4CgR.jpg

Fitting and fans do clear the grill, but just barely!

The last thing we need to do is to use something to give the fans a better seal against the condenser. Had we made a few more modifications to the mounting brackets, this might not have been an issue but we will figure that out when doing this same thinng on my 190E.

Awesome write up and pics. thanks for sharing.