andy_k
MB Enthusiast
Here's a fun job to do on a Saturday afternoon
Please bear in mind that like all "how tos" it's written with the clear
benefit of hindsight and although this is the order it probably should be done
it's not neccessarily the order I did it in
Due to their position, these are a common failure on the W124 and as soon as
you get yours out you'll find out why.
It's a job that's not covered by the Haynes manuals they say leave it alone and let an aircon specialist do it for you - but hey, that's like a red rag to a bull isn't it?
So bearing this in mind this isn't a job you should do if there is any gas left in the system although if you need a new condenser it's unlikely there will be especially if it's like mine with a big hole in it - play safe though and get it checked first.
Tools you'll need
Spanners
1 x 25mm
1 x 29mm
1 x 19mm
1 x 10mm
1 x 8mm
Screwdrivers or a 7mm spanner/socket to use on the hose clips
5 litres Anti Freeze/coolant
top up for auto transmission fluid
The job should take no more than 3 hours assuming everything goes according to plan.
Getting started
Firstly you need to remove the engine protection tray under the sump and drain your radiator - this panel should be held in place by two 8mm bolts with large washers (about the size of a 10p piece attached to them) once they are removed then the tray drops down and you can get at the radiator drain or bottom hose clip. Whilst you are under the car disconnect the lower feed for the transmission fluid cooler and wrap this in either a plastic bag or a cloth to reduce leakage and to stop any dirt getting in. You can also disconnect the clamp holding the upper pipe for the trans fluid cooler - this is located at the base of the radiator dead centre on the car. Whether or not you need to release it may be academic as you'll probably find it's rusted through. Check the condition of the pipes and if need be order some replacements.
From the top of the car remove the fan protection shroud - there's a small
clip in the top centre - push it towards the front of the car then turn the rear section of the shroud in the direction of the arrows - once it seperates just hang it over the viscous fan.
The front section of the shroud is held in place by two clips (one either side) once you've removed those you can lift it out. With that section out you can then get at the back section and remove that completely as well
Disconnect the top feed for the trans fluid cooler and seal that off as well
Disconnect the other two hoses to the radiator and the little return pipe on the top.
The radiator is held in with two clips, lever those off with a screwdriver and you should then be able to lift it clear of the car.
In front of the main radiator you will now be able to see the condenser with the auxilliary fans attached to it - this unit comes out all in one piece. Don't try and strip it down on the car it doesn't work.
As you face the car there is a small trim panel on the right hand side held in
with two plastic screws - remove it and you can now get at the top pipes attaching the condenser. To undo those you need the 29mm and 25mm spanners and be prepared for a struggle as they may be tight - if they won't budge use plan B and cut the pipe between the union and the condenser with a pair of decent pliers - it's soft copper and you don't need to re-use this bit and once the condenser is out you'll have more room to get a grip on the union
Remove the headlight on the passenger side - It doesn't need to come right out but you need to at least move it to get at the other union and to disconnect the auxillary fans. You need to remove the indicator lens as well to gain access to two of the retaining bolts. the indicator is held in with a clip you access from inside the wing - once you unclip it the lens just pops out.
Take the panel off below the headlight
With the head light moved to one side you can get at the bottom union for the condenser - again, be prepared for a fight these unions seem to corrode and are difficult to undo.
Just behind the headlight is the clip which holds down the fan connector, slide the clip off then spilt the connector then pull the wire through - there's a couple of cable ties you'll need to cut in order to free the wire.
Now, undo the two clips securing the condenser to the front crossmember and
lift it out with the fans attached. The fan shroud is attached to the framework by a series of push in connectors - these are virtually impossible to get out from the front without breaking so either order some new ones from the dealer or again, there is a plan B.
Undo the bolts at the side of the fan shroud - there are four 8mm bolts, two have nuts on the other side, the other two dont. with those removed you can
just about lift the shroud enough to get at the last two retaining bolts which are in the centre of the condenser. This will be the point where you find out why so many W124 condensers fail as the fan shroud will be full of all sorts of soggy leaf mulch etc - it's a real dirt trap and can only be bad for the radiator. Once it's all cleaned out and you've undone the last two nuts you can lift the shroud off and remove the little retaining clips from the inside without damaging them.
Reassembly is just the reverse procedure, start by bolting the fans to the new
condenser, then refit the shroud and push in the clips to secure it.
Replace the condenser and fix the two unions. The bottom one is most awkward and you may find it easier to disconnect it from the pump before you attach it to the condenser. Make sure you tighten the unions properly at this stage. If you have access to the tools it's worth pressure testing at this point whilst evertything is still easily accessible.
Once you are satisfied replace the trim which seals the area around the unions.
Replace the radiator, reconnect all the pipes and hoses, refill with fluids (you will lose about a cup full of auto transmission fluid and about 5 litres of anti freeze) then start the engine and check for any leaks.
Reattach the tray below the engine once you are satisfied there are no leaks
Don't switch the aircon on until you have had the system regassed.
Hopefully someone will find this useful
No pictures because it was a really dirty job and there was no-one around to
hold the camera.
Andy
Please bear in mind that like all "how tos" it's written with the clear
benefit of hindsight and although this is the order it probably should be done
it's not neccessarily the order I did it in
Due to their position, these are a common failure on the W124 and as soon as
you get yours out you'll find out why.
It's a job that's not covered by the Haynes manuals they say leave it alone and let an aircon specialist do it for you - but hey, that's like a red rag to a bull isn't it?
So bearing this in mind this isn't a job you should do if there is any gas left in the system although if you need a new condenser it's unlikely there will be especially if it's like mine with a big hole in it - play safe though and get it checked first.
Tools you'll need
Spanners
1 x 25mm
1 x 29mm
1 x 19mm
1 x 10mm
1 x 8mm
Screwdrivers or a 7mm spanner/socket to use on the hose clips
5 litres Anti Freeze/coolant
top up for auto transmission fluid
The job should take no more than 3 hours assuming everything goes according to plan.
Getting started
Firstly you need to remove the engine protection tray under the sump and drain your radiator - this panel should be held in place by two 8mm bolts with large washers (about the size of a 10p piece attached to them) once they are removed then the tray drops down and you can get at the radiator drain or bottom hose clip. Whilst you are under the car disconnect the lower feed for the transmission fluid cooler and wrap this in either a plastic bag or a cloth to reduce leakage and to stop any dirt getting in. You can also disconnect the clamp holding the upper pipe for the trans fluid cooler - this is located at the base of the radiator dead centre on the car. Whether or not you need to release it may be academic as you'll probably find it's rusted through. Check the condition of the pipes and if need be order some replacements.
From the top of the car remove the fan protection shroud - there's a small
clip in the top centre - push it towards the front of the car then turn the rear section of the shroud in the direction of the arrows - once it seperates just hang it over the viscous fan.
The front section of the shroud is held in place by two clips (one either side) once you've removed those you can lift it out. With that section out you can then get at the back section and remove that completely as well
Disconnect the top feed for the trans fluid cooler and seal that off as well
Disconnect the other two hoses to the radiator and the little return pipe on the top.
The radiator is held in with two clips, lever those off with a screwdriver and you should then be able to lift it clear of the car.
In front of the main radiator you will now be able to see the condenser with the auxilliary fans attached to it - this unit comes out all in one piece. Don't try and strip it down on the car it doesn't work.
As you face the car there is a small trim panel on the right hand side held in
with two plastic screws - remove it and you can now get at the top pipes attaching the condenser. To undo those you need the 29mm and 25mm spanners and be prepared for a struggle as they may be tight - if they won't budge use plan B and cut the pipe between the union and the condenser with a pair of decent pliers - it's soft copper and you don't need to re-use this bit and once the condenser is out you'll have more room to get a grip on the union
Remove the headlight on the passenger side - It doesn't need to come right out but you need to at least move it to get at the other union and to disconnect the auxillary fans. You need to remove the indicator lens as well to gain access to two of the retaining bolts. the indicator is held in with a clip you access from inside the wing - once you unclip it the lens just pops out.
Take the panel off below the headlight
With the head light moved to one side you can get at the bottom union for the condenser - again, be prepared for a fight these unions seem to corrode and are difficult to undo.
Just behind the headlight is the clip which holds down the fan connector, slide the clip off then spilt the connector then pull the wire through - there's a couple of cable ties you'll need to cut in order to free the wire.
Now, undo the two clips securing the condenser to the front crossmember and
lift it out with the fans attached. The fan shroud is attached to the framework by a series of push in connectors - these are virtually impossible to get out from the front without breaking so either order some new ones from the dealer or again, there is a plan B.
Undo the bolts at the side of the fan shroud - there are four 8mm bolts, two have nuts on the other side, the other two dont. with those removed you can
just about lift the shroud enough to get at the last two retaining bolts which are in the centre of the condenser. This will be the point where you find out why so many W124 condensers fail as the fan shroud will be full of all sorts of soggy leaf mulch etc - it's a real dirt trap and can only be bad for the radiator. Once it's all cleaned out and you've undone the last two nuts you can lift the shroud off and remove the little retaining clips from the inside without damaging them.
Reassembly is just the reverse procedure, start by bolting the fans to the new
condenser, then refit the shroud and push in the clips to secure it.
Replace the condenser and fix the two unions. The bottom one is most awkward and you may find it easier to disconnect it from the pump before you attach it to the condenser. Make sure you tighten the unions properly at this stage. If you have access to the tools it's worth pressure testing at this point whilst evertything is still easily accessible.
Once you are satisfied replace the trim which seals the area around the unions.
Replace the radiator, reconnect all the pipes and hoses, refill with fluids (you will lose about a cup full of auto transmission fluid and about 5 litres of anti freeze) then start the engine and check for any leaks.
Reattach the tray below the engine once you are satisfied there are no leaks
Don't switch the aircon on until you have had the system regassed.
Hopefully someone will find this useful
No pictures because it was a really dirty job and there was no-one around to
hold the camera.
Andy
