I will be going into the dash to change out evaporator/heater core. (85 300 TD wagon) I read in another post about the enormous amount of time/energy/cost to do this - but I have no other choice. The heater core leaked (so I disconnected it) - then found out that someone put R-22 in the system - have to change out all rubber, and compressor - at a minimum. Being that the car is basically 20 years old - and if I'm going to put the money into everything else - why not do the evaporator now? This would "seem" to make sense to me.

I saw the posts by dmorrison - any other "how to" information out there that I can use.

Thanks Steve

This is indeed an enourmous task. Eighteen or so hours by professional labor guides. If you are not well experienced with simpler/quicker replcements of such on other vehicles, then you have quite the project ahead of you. Last one I did took about fifteen hours total, and I have done a few of them. Times include evacuate and recharge.
FYI the first benz I bought I got a great deal on as the owner did not want to pay to do this job.

If you are without photographic memory:

get ziplock bags and a sharpie-Label and separate pieces and parts.
take a few notes as to the order of disassembly.
do not get in a hurry with old/brittle plastic parts.

For ease of work area start by removing the front seats, carpet and console:the job can be done without this but it actually takes more time.
Replace the rubber vac boots and pods while the thing is apart.
Let me know if you need assisstance.

Hardest part of the job may be that heater core. You will have to remove the heater box to get it out, I remember doing that job last year on my 78 and feeling panic creep in when I was looking at the front of the car with no dash, no heater box, and all those vac and electircal lines hanging out everywhere.
But I had it up and running by that night.

Steve it is a big job. But I may have to do it again depending on what I find in my daughters 240D. Please of please no evaporator leaks

Now that we have that out of the way I will give my advise.
1. Buy a digital camera and take pictures of every step. 2-3 dozen times I had to refer to them. I recommend high resolution pictures. I have a 2.1 meg camera and took all the pictures at the highes resolution. Each night label each photo with a label of what you did in that picture.
You will be happy you did.
My examples would be
01 condensor to hose connections
02 compressor location
03 font left of condensor.
etc.

Listen to this carefully IF THE EVAPORATOR IS NOT LEAKING THEN TRY FIXING THE HEATER CORE WITH LEAK STOP

Really if you dont' have to remove the box don't. Try the leak stop, you have nothing to loose. I had to replace the evaporator due to a leak.

Ok now if you must proceed.
1. Flush the hoses/condensor/evapaorator and replace the expansion valve if the compressor failed.
2. Replace the reciever/drier.
3. Replace the O rings.
4. Intall oil, seal up the system and evacuate.
5. charge with freon

If you go the whole 9 yards, and you need pictures, I have them. I can email them to you or send a copy of them on a CD.

I also did a post on installing everything.

http://www.peachparts.com/shopforum/showthread.php?postid=641719#post641719

Good luck.

PM me if you have any questions.

Dave

__________________
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

dmorrison
Thanks for the reply.

Problem is R-22 was in system - rubber is shot - along with radiator. Heater core is leaking - I disconnected it at firewall. So along with core - I am planning to change evaporator - Question - factory or aftermarket? - Copper/alum or all aluminum? What is the the performance of your ac after you changed your evaporator?

Thanks Steve

"Buy a digital camera and take pictures of every step"
Dave beat me to saying this... thank goodness for technology...

Thanks for all the information
The way I see it - (as fas as the dash/evap/heater core removal) - I have already removed and replaced (several times) instrument panel, glovebox, 2 plastic covers under dash, 2 side carpets at trans tunnel, console, seats - when the console is out - I can see the beginnings of a real mess - vac lines, wires, that are in front of the ac box. I know the real job is ahead of me - but if I've already done the items I've mentioned - I would say for just those items - about 6 to 8 hours? About how many hours for the dash/evap/heater core work? Anybody any idea? Thanks Steve

I think a huge change in Dave's was brought about by his cleaning of the upstream side of the fins in his evaporator....
I did not know that different metal evaporators were available for replacement... were you thinking Condensor ?

I was thinking about the evaporator - I have to go there anyway to get at the heater core. Anybody repair the foam for the air flap seals?

Anybody? - While I'm still motivated - Ha Ha. Steve

Dave
How can I get the CD? (Not sure how to e-mail you)

Thanks Steve