Vacuum element replacement.
 

I've done a vacuum check on my '91 300CE. I found that the element for the diverter air flap is leaking. My repair cd says that you have to pull the instrument panel. Does anyone have any other suggestions?
Thanks

Since that vacuum element is at the TOP of the box that IS the only course of action.

Thanks for your response. I was afraid of that. While I'm in there should I look for or replace anything else?

All six of the vacuum pods, at a minimum, because they're probably all the same age and will wear out soon enough, and you don't want to have to pull the panel again any time soon. Then, consider the A/C evaporator if it's still the original. And, of course, take the time to replace all of the light bulbs while the panel is removed.

The repair cd says that the steering wheel needs to be pulled. I can't find the section for that. The reference talks about everything but that. Anybody have a clue where it is?

I've done a search about the dash removal. I saw one post that said you don't have to remove the steering wheel. This that the case, or does it complicate the process by leaving the wheel on?

It's easier with the wheel removed. Airbag pyrotechnics need to be disabled first for this and evaporator replacement assuming you have passenger side airbag also
To disable the airbag follow these instructions:

1. Turn off the ignition switch and remove the key
2. Remove the negative battery from the battery and tape it or wire it away from the battery
3. Remove the front passenger side floor mat, carpet and plastic panel on the floor
4. Disconnect the red plug

There are 2 torx head screws (they may be security head torx) affixing the airbag to the steering wheel from behind. You will need a long allen wrench style torx wrench to reach the bolts from the access holes on the backside of the steering wheel. Once loosened the airbag pulls off from the front. Store the air bag in a secure location on a horizontal surface with the airbag side pointing upward (aluminum back down). Follow the links below for steering wheel removal and pod replacement. Good luck, Mark

http://www.peachparts.com/shopforum/showthread.php?t=243695&highlight=124+steering+wheel+removal

http://www.peachparts.com/shopforum/showthread.php?t=226049&highlight=124+steering+wheel+removal

I've removed about a half-dozen 124 dashes with the steering wheel on, I don't see the point in removing it.

Extend the steering wheel out fully, it will help clearances. Also, you'll want to pad the plastic column cover with a piece of boxboard or equivalent when you slide the dash end over it and out the passenger door.

There is a DIY on it, with photos.

If you need to replace the diverter pod, I believe it is the one buried inside, definately a dash-off job. Do you have the passenger airbag (optional in '91 on the T124 and W124, not sure on the coupe though)? If not, you can remove the glovebox and access the vacuum lines on the vacuum-solenoid array, and check (with a Mityvac or equivalent) each pod for operation and leaks.

I do not have passenger's air bag. I have pulled the glove box and done a Mityvac test and found only the diverter pod leaking. However, as suggested, I believe wisdom would dictate replacing the other pods. The best I can estimate just the pods will be about $325. But I couldn't imagine how much the dealer would charge. From my readings I can anticipate about an 8-10 hour job. Am I close in my estimates?

Different car, but I recently replaced my heater core and thought about replacing all the vacuum pods. I didn't do it because I was hemorrhaging money on the car and had to draw the line somewhere. Now, about four months later, one of the pods is leaking. I don't need to remove the dash to change this one, but I'm afraid the rest are going to go soon.

If you can swing it, replace them all. I don't know about the heater core on your model, but that might be something to consider as well.

So far the AC is cold, but who knows what the morrow may bring. As you said, "You have to draw the line somewhere."