Holy mackeral is that a job and a half.

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Proud owner of ....
1971 280SE W108
1979 300SD W116
1983 300D W123
1975 Ironhead Sportster chopper
1987 GMC 3/4 ton 4X4 Diesel
1989 Honda Civic (Heavily modified)
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Section 609 MVAC Certified
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"He who fights with monsters might take care lest he thereby become a monster. And if you gaze for long into an abyss, the abyss gazes also into you." - Friedrich Nietzsche

Isn't replacing the evaporator listed at about 17 hours in the flat rate manual for some of our cars ?
I think I would turn my car into a parts car rather than tackle that... under dash stuff always kills me anyway... too big and too old for that anymore.

But I am going to clean my evaporator when I put the AC back into my 240...but I swear I am going to figure out a shortcut.... pictures at 11.

To add to this post about the cleanliness of the evaporators once removed. Here is the 83 240D evaporator that was removed from my Daughters car this Christmas.
Looks a lot like the one I removed from the 1982 300TD.

Dave

Attached Thumbnails

 

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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