=====Replacing the A/C Evaporator===== ====on the 1983 240D & 1982 300TD (W123)==== ===by ""dmorrison""=== ===6/17/06=== //(Revised 12/28/06)// ---- **Photo step by step post showing a W123 evaporator removal (1983 240D and 1982 300TD) (LARGE FILES)** These pictures are from replacing the evaporators in my Daughters 1983 240D and my 1982 300TD. Not every little step is included. As you progress you will figure things out. This is not a terribly difficult job. Just time consuming. AC knowledge is required for this job and a 609 license is worth while. Not mandatory but preparing for the test teaches you a tremendous amount about the AC system. Notice some pictures are labeled 300TD, 240D and 300TD/240D. I am trying to show pictures that are specific to the model listed. IF I have not listed a car then it applies to both. What is specified for the 300TD will apply to the 300D and 300CD usually. This is for a "Automatic Climate Control III" for the 300TD as specified in the Mercedes Service Manual. And the "Heating/Ventilation and Air Conditioning I" as specified the Mercedes Service Manual for the 240D. The only difference in the 240D system is the car has the R-4 compressor not the York unit shown in the Service Manual. Of course disconnect the battery, drain the radiator and you will have to recover any freon in the AC system. Note, when looking at the pictures if the car is maroon in color it is the 240D. Signal red ( stop sign red) it is the 300TD Any recommendations for this post will be appreciated. Dave ---- 001 Remove Mercedes symbol, this is not really necessary. http://www.peachparts.com/diy/w123evaporator/001.jpg 002 Peel the horn cover off http://www.peachparts.com/diy/w123evaporator/002.jpg 003 Pull the center of the cover off hub http://www.peachparts.com/diy/w123evaporator/003.jpg 004 After removing bolt, Mark the shaft wheel relationship with a punch. http://www.peachparts.com/diy/w123evaporator/004.jpg 005 Remove ashtray http://www.peachparts.com/diy/w123evaporator/005.jpg 006 Remove center console carpet and remove screw http://www.peachparts.com/diy/w123evaporator/006.jpg 007 Remove ashtray bracket mounting screws http://www.peachparts.com/diy/w123evaporator/007.jpg 008 Lift front of wood trim above shifter and slide to the rear to remove http://www.peachparts.com/diy/w123evaporator/008.jpg 009 Disconnect wires http://www.peachparts.com/diy/w123evaporator/009.jpg 010 Slide towards rear to protect the pin, disconnect switch wires http://www.peachparts.com/diy/w123evaporator/010.jpg 011 Pull radio http://www.peachparts.com/diy/w123evaporator/011.jpg 012 Label radio wires http://www.peachparts.com/diy/w123evaporator/012.jpg 013 Pull off AC control knobs http://www.peachparts.com/diy/w123evaporator/013.jpg 014 Use socket to remove AC control nuts http://www.peachparts.com/diy/w123evaporator/014.jpg 015 Pull AC panel and disconnect light units http://www.peachparts.com/diy/w123evaporator/015.jpg 016 Pull switch out from the rear http://www.peachparts.com/diy/w123evaporator/016.jpg 017 Pull all switches and remove the wire harness http://www.peachparts.com/diy/w123evaporator/017.jpg 018 Using your fingers in the outside holes, push the wood trim out from behind http://www.peachparts.com/diy/w123evaporator/018.jpg 019 Wood trim lifts at bottom first then out http://www.peachparts.com/diy/w123evaporator/019.jpg 020 Disconnect the temp dial wires using your fingers. 2 harnesses http://www.peachparts.com/diy/w123evaporator/020.jpg 021 Push in the top tab and remove the dial by pushing the unit into the console http://www.peachparts.com/diy/w123evaporator/021.jpg 022 300TD/240D. Remove the outboard switches to remove the screws http://www.peachparts.com/diy/w123evaporator/022.jpg 023 Remove both front seat inboard slide bolts in rear tunnel http://www.peachparts.com/diy/w123evaporator/023.jpg 024 Remove drivers seat back panel. Unscrew it then slide the panel down. Or remove the entire driver seat. http://www.peachparts.com/diy/w123evaporator/024.jpg 025 Remove the bolt holding the drivers seat armrest http://www.peachparts.com/diy/w123evaporator/025.jpg 026 Remove screw covers on both under dash panels http://www.peachparts.com/diy/w123evaporator/026.jpg 027 Remove screws http://www.peachparts.com/diy/w123evaporator/027.jpg 028 Remove under panel side screws http://www.peachparts.com/diy/w123evaporator/028.jpg 029 Remove under dash panels http://www.peachparts.com/diy/w123evaporator/029.jpg 030 Drivers side under dash panel, side screw http://www.peachparts.com/diy/w123evaporator/030.jpg 031 Remove center console carpet screws http://www.peachparts.com/diy/w123evaporator/031.jpg 032 Lift center console from the rear. Watch top center of console and dash clearance. http://www.peachparts.com/diy/w123evaporator/032.jpg 033 Guide center console carpets while lifting. http://www.peachparts.com/diy/w123evaporator/033.jpg 034 Guide center of console over shifter. http://www.peachparts.com/diy/w123evaporator/034.jpg 035 If you can't remove the center console. Disconnect the tabs holding the carpet, 4 total ( Note: The manual does call for the driver seat to be removed. For the removal of the center console, the side carpets are the reason) http://www.peachparts.com/diy/w123evaporator/035.jpg 036 Center console removed. The AC control panel is broken on this car.( I glued the unit together, A new unit has to come from Germany) http://www.peachparts.com/diy/w123evaporator/036.jpg 037 Remove the floor heat duct under the drivers feet http://www.peachparts.com/diy/w123evaporator/037.jpg 038 Removing the floor duct, drivers side , continued. http://www.peachparts.com/diy/w123evaporator/038.jpg 039 Remove the cable harness on the drivers side of the floor duct http://www.peachparts.com/diy/w123evaporator/039.jpg 040 More center console pictures http://www.peachparts.com/diy/w123evaporator/040.jpg 041 Removing AC control bracket, (this will not normally be removed, it is pop rivited to the evap box. Switches must be removed from the panel) http://www.peachparts.com/diy/w123evaporator/041.jpg 042 ID wire harness to switch connectors http://www.peachparts.com/diy/w123evaporator/042.jpg 043 ID wire harness to switch connectors, continued http://www.peachparts.com/diy/w123evaporator/043.jpg 044 Remove bulb spider for center console lights http://www.peachparts.com/diy/w123evaporator/044.jpg 045 Clips that hold the Bowden cables to the side controls http://www.peachparts.com/diy/w123evaporator/045.jpg 046 Plastic panel on Bowden cable mechanism. Positioning picture for repositioning after unbolting mechanism http://www.peachparts.com/diy/w123evaporator/046.jpg 047 Wire harness to control http://www.peachparts.com/diy/w123evaporator/047.jpg 048 Remove oil line and loosen speedometer cable in engine compartment so you can pull out instrument cluster far enough to remove speedometer cable. Remove wires http://www.peachparts.com/diy/w123evaporator/048.jpg 049 Pull off light switch http://www.peachparts.com/diy/w123evaporator/049.jpg 050 240D idle knob. Pull knob off straight back ( it's hard) and unscrew chrome ring http://www.peachparts.com/diy/w123evaporator/050.jpg 051 Unhook parking brake cable chain. http://www.peachparts.com/diy/w123evaporator/051.jpg 052 Unscrew speaker grill screws on both speakers and remove grills http://www.peachparts.com/diy/w123evaporator/052.jpg 053 Remove push clips center pins then base. 3 on bottom and 4 on top http://www.peachparts.com/diy/w123evaporator/053.jpg 054 Remove glove box light and disconnect wires http://www.peachparts.com/diy/w123evaporator/054.jpg 055 Remove glove box. Pry the top below the striker plate. Then remove the light wires http://www.peachparts.com/diy/w123evaporator/055.jpg 056 Pry the A pillar molding off the A pillar Use a wide metal or plastic tool. Pry at the bottom then the top http://www.peachparts.com/diy/w123evaporator/056.jpg 057 Pry at the top then move the bottom of the trim towards the center of the car. Watch out for the speakers. http://www.peachparts.com/diy/w123evaporator/057.jpg 058 Remove the speaker mount bolts and speakers http://www.peachparts.com/diy/w123evaporator/058.jpg 059 240D Disconnect the center vent cable from the vent mechanism. http://www.peachparts.com/diy/w123evaporator/059.jpg 060 Remove the drivers side lower dash mount bracket completely. Note the screw washer combination and orientation of bracket http://www.peachparts.com/diy/w123evaporator/060.jpg 061 Remove the passenger side lower mount bracket. Note the same info as above http://www.peachparts.com/diy/w123evaporator/061.jpg 062 Disconnect both speaker wires from the dash. http://www.peachparts.com/diy/w123evaporator/062.jpg 063 Remove the center support bracket completely so it does not hit the evap box http://www.peachparts.com/diy/w123evaporator/063.jpg Remove the dash from the passengers side first and move it out the passengers door. You will have to lift the dash off the defroster tubes on the evap box. Once lifted off them, it will come out. Watch the turn signal stick. Don't break it. Don't twist the dash as this may cause cracking. One word about reinstalling the dash. As you install the dash, the lip of vinyl at the front of the dash next to the windshield will curl up and make it difficult to get under the windshiled rubber. Using the same flat tool used to remove the A pillar moldings works well. Hold the dash in position and slie the lip under the weather strip. 064 300TD Replace the foam tube under the dash, I used a plastic unit http://www.peachparts.com/diy/w123evaporator/064.jpg 065 300TD Move the amp wire harness http://www.peachparts.com/diy/w123evaporator/065.jpg 066 300TD Remove the amp setup to allow the evap box to clear http://www.peachparts.com/diy/w123evaporator/066.jpg 067 300TD Center console area. http://www.peachparts.com/diy/w123evaporator/067.jpg 068 300TD Center console area upper section http://www.peachparts.com/diy/w123evaporator/068.jpg 069 300TD Holding the center area wire harnesses http://www.peachparts.com/diy/w123evaporator/069.jpg 070 300TD the center console area switches going though the wire locking strap http://www.peachparts.com/diy/w123evaporator/070.jpg 071 300TD Right side wire harness holder http://www.peachparts.com/diy/w123evaporator/071.jpg 072 300TD Remove the center connection under the vacuum switchs http://www.peachparts.com/diy/w123evaporator/072.jpg 073 300TD Picture for identifying plastic tubes color codes http://www.peachparts.com/diy/w123evaporator/073.jpg 074 300TD Picture for more plastic tube color ID http://www.peachparts.com/diy/w123evaporator/074.jpg 075 300TD Vacuum tubes to center vent element http://www.peachparts.com/diy/w123evaporator/075.jpg 076 300TD Disconnect plastic tubes to center vent element http://www.peachparts.com/diy/w123evaporator/076.jpg 077 300TD/240D Uncouple the wire harness at the driver side floor vent http://www.peachparts.com/diy/w123evaporator/077.jpg 078 300TD/240D Uncouple the wire harness at the drivers side of evap box http://www.peachparts.com/diy/w123evaporator/078.jpg 079 300TD Remove the ETR sensor http://www.peachparts.com/diy/w123evaporator/079.jpg 080 300TD Unclip the connector base on the drivers side case http://www.peachparts.com/diy/w123evaporator/080.jpg 081 300TD/240D Unbolt and pull out both left and right support straps http://www.peachparts.com/diy/w123evaporator/081.jpg 082 300TD/240D Unbolt the top bolt of the support straps, note the order http://www.peachparts.com/diy/w123evaporator/082.jpg 083 300TD/240D Remove the heater core hose form the drivers side and passenger side (shown, see below for drivers side on the 240D)) http://www.peachparts.com/diy/w123evaporator/083.jpg 084 300TD/240D Note the positions of the clamp screws for reinstallation http://www.peachparts.com/diy/w123evaporator/084.jpg 085 300TD/240D Tape over the heater core tubes to prevent water from dripping while removing http://www.peachparts.com/diy/w123evaporator/085.jpg 086 300TD Remove the interior passenger side tube http://www.peachparts.com/diy/w123evaporator/086.jpg 087 240D Disconnect the drivers side heater hose http://www.peachparts.com/diy/w123evaporator/087.jpg 088 240D Remove the 2 passenger side heater hoses http://www.peachparts.com/diy/w123evaporator/088.jpg 089 240D Move the heater hoses up above the vent area to prevent drips http://www.peachparts.com/diy/w123evaporator/089.jpg 090 Evacuate the Ac system of all freon. Disconnect the Ac hoses at the expansion valve http://www.peachparts.com/diy/w123evaporator/090.jpg 091 Unscrew the wire ground on the drivers side of the evap box http://www.peachparts.com/diy/w123evaporator/091.jpg 092 Unzip the wire bundle lock on the drivers side of the evap box http://www.peachparts.com/diy/w123evaporator/092.jpg 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) http://www.peachparts.com/diy/w123evaporator/093.jpg 094 240D Pull fiber optic spider from AC control bracket http://www.peachparts.com/diy/w123evaporator/094.jpg 095 Unbolt the switchover valve from the mount http://www.peachparts.com/diy/w123evaporator/095.jpg 096 Disconnect the vacuum hose from the fresh air element http://www.peachparts.com/diy/w123evaporator/096.jpg 097 Pull the flex hose from the drivers side and passengers side http://www.peachparts.com/diy/w123evaporator/097.jpg 098 Detach the wire harness socket from the evap box http://www.peachparts.com/diy/w123evaporator/098.jpg 099 Passenger side disconnect the fan wire harness http://www.peachparts.com/diy/w123evaporator/099.jpg 100 Unbolt both mounting strap bolts at transmission tunnel. Do not unhook at the top. They are difficult to reinstall. Just place aside http://www.peachparts.com/diy/w123evaporator/100.jpg 101 Unbolt passenger side top mount nut http://www.peachparts.com/diy/w123evaporator/101.jpg 102 Unbolt middle section top mount nut http://www.peachparts.com/diy/w123evaporator/102.jpg 103 Unbolt drivers side top mount nut http://www.peachparts.com/diy/w123evaporator/103.jpg 104 Unbolt lower mount bolt http://www.peachparts.com/diy/w123evaporator/104.jpg 105 It is best to completely remove the lower mount bracket so you don't hit the evap box http://www.peachparts.com/diy/w123evaporator/105.jpg 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 http://www.peachparts.com/diy/w123evaporator/106.jpg 107 Separating the heater box from the evap box. How to push the tabs http://www.peachparts.com/diy/w123evaporator/107.jpg 108 Remove the tabs to separate the heater box. This tab and the opposite one on the box http://www.peachparts.com/diy/w123evaporator/108.jpg 109 Remove the 2 tabs I'm pointing at to separate the heater/evap box http://www.peachparts.com/diy/w123evaporator/109.jpg 110 Remove the left side heater box bolt. Save all parts http://www.peachparts.com/diy/w123evaporator/110.jpg 111 Remove the right side heater box nut. Save all parts. Now separate the heater and evaporator box sections http://www.peachparts.com/diy/w123evaporator/111.jpg 112 Separating the fresh air section from the evap section. Remove these 4 clips. http://www.peachparts.com/diy/w123evaporator/112.jpg 113 Separating the fresh air section. Remove these 2 clips (6 total) http://www.peachparts.com/diy/w123evaporator/113.jpg 114 Separating the fresh air section. Remove these 2 clips (Now 8 total) http://www.peachparts.com/diy/w123evaporator/114.jpg 115 Separating the fresh air section. Remove these 4 clips (Now 10 total) http://www.peachparts.com/diy/w123evaporator/115.jpg 116 Separating the fresh air section. Disconnect the element shaft from the door http://www.peachparts.com/diy/w123evaporator/116.jpg 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" http://www.peachparts.com/diy/w123evaporator/117.jpg 118 240D Separating the fresh air section. Remove the clip that holds the cable http://www.peachparts.com/diy/w123evaporator/118.jpg 119 Separating the fresh air section. Unplug the fan wire harness http://www.peachparts.com/diy/w123evaporator/119.jpg 120 Separating the fresh air section. Remove the wire harness from the base mount http://www.peachparts.com/diy/w123evaporator/120.jpg 121 Separating the fresh air section. Unhook the wire harness form the box http://www.peachparts.com/diy/w123evaporator/121.jpg 122 240D Separating the fresh air section. Remove the blower motor resistor unit from the evap box http://www.peachparts.com/diy/w123evaporator/122.jpg 123 Remove and replace the fresh air element while you're here http://www.peachparts.com/diy/w123evaporator/123.jpg 124 Separating the evap section. Remove these 3 clips http://www.peachparts.com/diy/w123evaporator/124.jpg 125 Separating the evap section. Remove these 2 clips (5 total) http://www.peachparts.com/diy/w123evaporator/125.jpg 126 Separating the evap section . Remove the foam and these 3 clips (8 total) http://www.peachparts.com/diy/w123evaporator/126.jpg 127 Separating the evap section. Slide the upper case off the evaporator http://www.peachparts.com/diy/w123evaporator/127.jpg 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 http://www.peachparts.com/diy/w123evaporator/128.jpg 129 Note the position of the sheetmetal piece and foam. Foam also on the bottom http://www.peachparts.com/diy/w123evaporator/129.jpg 130 Remove the black tar sealant from around the expansion valve. Note rubber sealing wall. Remove the rubber wall with the evaporator http://www.peachparts.com/diy/w123evaporator/130.jpg 131 Note how much dirt is in the fins of the evaporator. http://www.peachparts.com/diy/w123evaporator/131.jpg 132 300TD "Recirculation air flap" element http://www.peachparts.com/diy/w123evaporator/132.jpg 133 300TD Heater core tubing http://www.peachparts.com/diy/w123evaporator/133.jpg 134 300TD Close up. "Recirculation air flap" element http://www.peachparts.com/diy/w123evaporator/134.jpg 135 300TD Close up. "Main air flap" element http://www.peachparts.com/diy/w123evaporator/135.jpg 136 300TD "Center nozzle flap" section and element http://www.peachparts.com/diy/w123evaporator/136.jpg 137 300TD "Defrost nozzle flap" element, located on the drivers side of the evap/heater box. http://www.peachparts.com/diy/w123evaporator/137.jpg 138 300TD Center section of evap box http://www.peachparts.com/diy/w123evaporator/138.jpg 139 300TD The upper element is the "Defrost nozzle flap" element. The lower element is the "legroom flap" http://www.peachparts.com/diy/w123evaporator/139.jpg 140 300TD The expansion valve area. http://www.peachparts.com/diy/w123evaporator/140.jpg ---- **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 [[http://www.peachparts.com/shopforum/showthread.php?t=80341 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 pictures here should be adequate for anyone doing this job. Dave [[http://www.peachparts.com/shopforum/showthread.php?t=156207 Discuss this DIY here.]] **-""dmorrison""** ---- CategoryDiy