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

I have edited this post to make corrections so that the names of various parts match the Service Manual name, and a few spelling corrections


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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