For those who said these cars have problematic A/C systems - I totally believe you now!! Since I don't have the pressure gauges, vacuum pumps, recapture system, etc. to mess with it; and also don't fully understand the many components and complexities with these A/C systems and sensors, I decised to let a local mechanic do the work. He's familiar with these cars and does the work at his home garage (better rate). He ended up recapturing the freon and vacuum testing about 6 times when it was all said and done. Here is how it went:

I was hoping to be luckiy and just change the o-rings, retrofit the R134, replace the dryer, vacuum test and be done for $120.....but I am not that lucky!

First-It was not blowing any air to begin with so he diagnosed the blower to be bad. He actaually got it spinning, but it was drawing a lot of amps then it froze up and started to smoke...... New Bosch blower motor -$77. Didn't want to go used on that one.

He ended up finding a leak in the system which turned out to be in the front condenser and could not be repaired. Sourced a good used on at the wrecking yard for him $40.

Got that installed and the then the compressor clutch was bad and would not engage (it did look a but rusty to begin with). Also said the Hi pressure switch was not functioning and need the r134 version. Again, found good used ones from the wrecker for $50 for both. The Compressor looked to be recently replaced.

Installed and tested again (manually blowing cold) and then found that the speed sensor in the compressor I got him was not good. The one in my old one was good, so he swapped them out.

I thought i was in the clear at this point. He them found that something in the Klima was not working to keep the system going on its owm. There were no used ones around and a rebuilt was going to be $150-$200. Since he realized they could be rebuilt he opened it up to find one of the copper connections was fried or broken. He was able to solder a new section in there. It actually worked and NOW MY A/C is working! This guy was pretty good!

Thank goodness my CCU was okay!

I ened up paying him $600. that didn't include the parts mentioned except the dryer. It was a lot of labor to install, re-install, vacuum test, freon, new dryer, r-134 retrofit, and all the diagnostics. I was pretty impressed with the Klima fix too!

The only thing left is the center dash vents don't blow. I need to search around for that one. I think it was the pods of something. I'll tear into the dash soon.

Sorry for the long post, but wanted to share how unlucky one can get. Hopefully it will work for a while and keep the wife and kids cool. I can't imagine what this would have cost at the dealer!!!

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1987 300TD 147,000 miles- Palomino leather interior, 1995 facelift and body cladding, E350 wheels, Rebuilt suspension and sport springs, rebuilt turbo, New Monarch injection pump and injectors....and the list goes on and on...

If you paid $600 to get the job done right, why did pay more for R-134a when you already had R-12?

Sixto
87 300D

I did consider keeping R-12. Yes- R-12 cools better, but from what I understand is much more expensive, harder to source every year that passes, and very bad for the environment. Didn't want to take a chance if the there are more leaks to come. We just need it cold in the car, not very cold. The existing system was completely empty of R-12. The retofit kit/valves was only about $20 I believe

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1987 300TD 147,000 miles- Palomino leather interior, 1995 facelift and body cladding, E350 wheels, Rebuilt suspension and sport springs, rebuilt turbo, New Monarch injection pump and injectors....and the list goes on and on...

But you said he recaptured the R-12. What's he going to do with it? Buying R-134a and adapters was an added expense.

Did you replace the expansion valve for one calibrated for R134a? I don't know this for a fact but there might be other seals in the system not suited for R-134a.

Sixto
87 300D