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I recommend you go with a NEW unit, and go back to R12. That's what I did with my 83 240D (Which has less HP than the 300D) and the A/C works very well. Quiet, cool, even at 95 degrees at 1 mile elevation. Dare I say it - the 240D hardly notices when it is on. You can tell when it kicks in, but it's NOT a huge drag. My R4 reman unit lasted less than a month before it died.
* Get a new R4 compressor
* Figure out the correct sealing washers for it
* Vacuum out all the R134a, it's not as good (IMHO) as R12, purge the system thoroughly.
* Change the fittings back to R12
* May have to change the drier and receiver, etc. (I'm no expert in these things)
* Reassemble, charge with R12.
* Enjoy cool and quiet A/C
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83 240D - 4 speed manual - Manilla Beige
189K miles, Tachometer mod, cool wooden shift knob from PeachParts, CocoMats, Original factory paint, manual windows, manual sunroof. Starting to add AudioWrap to this car too!
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