W ater ingress into vehicle interior via roof air conditioning

Topic number

Version

Design group

Date

Ll83.50-N-059306

3

83.50 Rear air conditioning

09-24-2014

Validity Model 906.6/7 with CODE H08 (High-performance air conditioning in passenger compartment) MODEL 906.6/7 with CODE HHO (NC system parts kit) and with CODE HHS (NC system preinstallation)

Reason for change

Reason for block

Complaint: Water ingress into vehicle interior via roof air conditioning.

Cause:

Validity adapted

Water enters between the evaporator unit and the vehicle roof. Condensation enters due to unfavorable pressure ratios.

Remedy: 1. Drain roof NC system. The following safety and technical information must be observed: AS83.00-Z-0001 -01A,

AH83.30-N-0004-01A, AH83.30-N-0003-01 A.

Note: Protect ci rcuit and components of air conditioning against moisture during repair work.

Note: The testing and filler connections of the refrigerant circuit of the roof air conditioning are located in the en­gine compartment on the longitudinal member on the right side (see Figure 01 .jpg).

Note: Unscrew the protective caps (30 and 31) from the testing and filler connections of the high-pressure line (C) and low-pressure line (D) (see Figure 01.jpg). Connect NC service unit (NC service unit for R 134a go tis:// E_83_05.0) (see Figure 01.jpg) and extract refrigerant; the quantity of compressor oil extracted must be noted down.

2. Disconnect NC service unit (NC service unit for R1 34a gotis://E_83_05.0) and screw the protective caps (30 and 31) onto the testing and filler connections of the high-pressure line (C) and low-pressure line (D) (see Figure 01 .jpg) .

3. Check whether a timer module has been installed .

Information: To do so, remove cover under air vent (see AR.68.10-D-1590A). Conduct visual inspection as to whether the area of the instrument panel carrier (T) (left A-pillar) has a timer module (Z) installed in it {see pic­ture 10.jpg).

If yes, create a PTSS case for further procedure.

4. Replace AAC [KLA] control and operating unit (S98) (see AR83.25-D-1124C).

5. Remove trim of evaporator unit on inside (see AR83.50-D-5010B).

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6. Remove air duct of air conditioning system (roof equipment) (see AR83.50-D-4000-01 B).

7. Remove center headliner {17) (see Figure 03.jpg and Figure 04.jpg).

Note: Picture and information illustrate/describe a vehicle with CODE 003 (High roof), CODE T16 (Right sliding door) and CODE FY1 (Interior protection).

Note: To do th is, unclip interior sensor (M) and detach electrical connection. Partially unclip B-pillar trim on driver and passenger side (21 and 20) at the top (see AR68.30-D-4700A). Uncl ip clip (19) of front headliner (16) at the rear. Remove expansion rivets (18) of center headliner {17) at the front. Unclip cl ip (22) of center headliner (17) at the rear and in the vicinity of the evaporator unit. Remove expansion rivet (15) on C-pi llar on passenger side. Press up center headliner (17) on left side between cutouts in center headliner (17) (see Figure 04.jpg (green ar­rows)) using a plastic wedge while pulling slightly inwards in order to detach center headliner (17) from body and remove.

8. Detach refrigerant lines (G and H) from expansion valve (see Figure 05.jpg).

~: To do this, remove the insulation (2) around the connections of the refrigerant lines (G and H). Unscrew nuts (3 and 4) and disconnect refrigerant lines (G and H) from expansion valve.

Important: Seal the openings in the expansion valve and in the refrigerant lines (G and H) with stop plugs (W129 589 00 91 00) otherwise damage could be caused by moisture ingress.

9. Unclip clip (K) fastening condensation hose (F) to rear automatic air conditioning air recirculation unit (A32/3) and disconnect condensation hoses (F and E) from rear automatic air conditioning air recirculation unit (A32/3) (see Figure 05.jpg).

10. Remove cable tie (5), disconnect electrical connections (6,7 and 8) at rear automatic air conditioning air recircu­lation unit (A32/3) and unclip retaining clip (1) (see Figure 05.jpg).

11 . Unscrew mounting bolts of rear automatic air conditioning air recirculation unit (A32/3) and remove frame (see Figure 06.jpg).

12. Remove outer trim of condenser unit (see AR83.50-D-5000B).

Safety notice: Risk of death by falling off the vehicle roof. Risk of injury for other persons when working in the roof area. Use a suitable work platform for these operations.

13. Remove left air grille (12) and right air grille {10). Unscrew nut (14) of refrigerant line (9) from strut (1 1). Unscrew bolts (13) on left and right of strut (11 ). Remove strut (11) (see Figure 07 .jpg).

Safety notice: Risk of death by falling off the vehicle roof. Risk of injury for other persons when working in the roof area. Use a suitable work platform for these operations.

14. Remove rear automatic air conditioning air recirculation unit (A32/3).

Note: Get a second person to help.

Safety notice: Risk of death by falling off the vehicle roof. Risk of injury for other persons when working in the roof area. Use a suitable work platform for these operations.

15. Clean roof panel in area of contact surface of rear automatic air conditioning air recirculation unit (A32/3) with approved MB cleaning agents.

Important: The surface of the sealing area must be clean and free of grease.

Safety notice: Risk of death by falling off the vehicle roof. Risk of injury for other persons when working in the roof area. Use a suitable work platform for these operations.

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16. Replace seal ing frame (23) on rear automatic air conditioning air recirculation unit (A32/3) (see Figure 08.jpg) (only use the specified part number).

Note: To do this, remove the old sealing frame (23) and clean the bonding surface for the new sealing frame (23) on the rear automatic air conditioning air recirculation unit (A32/3). Start by sticking the shorter section of the sealing frame (23) at the position shown (see red arrow) (see picture 08.jpg). Pull the protective foil off the sealing frame (23) only as far as can be stuck down in one go. It is absolutely essential to avoid getting dirt on the adhesive side of the sealing frame (23). The joints of the sealing frame (23) must not be in the radius area. The sealing frame (23) must have no clearance or gap (26) to the contact stop or edge (see Figure 08.jpg). If the sealing frame (23) is too long, the joint should be shortened to fit according to the original L-shape.

Note: Stick down the sealing frame (23) without stretching it, otherwise the cross section of the seal is reduced.

17. Insert rear automatic air conditioning air recirculation unit (A32/3) into vehicle roof and align (see Figure 09.jpg).

Note: The rear automatic air conditioning air recirculation unit (A32/3) is al igned with the aid of the end stops (27 and 28) (in the direction of travel) and the end stop (29) (passenger side). These stops must touch the roof cu­tout (see Figure 09.jpg).

Safety notice: Risk of death by fa lling off the vehicle roof. Risk of injury for other persons when working in the roof area. Use a suitable work platform for these operations.

18. Install installation frame (see Figure 06.jpg).

Important: The tightening torque (4 Nm) and tightening sequence must be strictly observed (see Figure 06.jpg), arrow {blue) = direction of travel.

19. Replace flu id reservoir (see AR83.50-D-5080B).

Safety notice: Risk of death by falling off the vehicle roof. Risk of inju ry for other persons when working in the roof area. Use a suitable work platform for these operations.

20. Install strut {1 1 ). Tighten bolts ( 13) on left and right of strut ( 11 ) to torque ( 13.5 Nm). Screw nut (14) of refrigerant line (9) onto strut (11 ). Install left air gri lle (12) and right air grille (10) (see Figure 07.jpg).

Safety notice: Risk of death by fall ing off the vehicle roof. Risk of injury for other persons when working in the roof area. Use a suitable work platform for these operations.

21. Install outer trim on condenser unit (see AR83.50-D-5000B).

Safety notice: Risk of death by fall ing off the vehicle roof. Risk of injury for other persons when working in the roof area. Use a suitable work platform for these operations.

22. Connect condensation hoses (E and F) to rear automatic air conditioning air recirculation unit (A32/3) (see Figu­re 05.jpg).

23. Check condensation drain hoses for free flow (see picture 02.jpg).

Note: To do this, pour water through a hose (34) into the opening in the filter of the rear automatic air conditio­ning air recirculation unit (A32/3). Water must be seen to emerge at the outlet points (32 and 33) of the conden­sation hoses, otherwise proper drainage of the water must be restored.

24. Perform rain test for a period of min. 10 minutes.

Note: If water again enters the vehicle interior, a PTSS case must be created in order to clarify further procedu­res.

25. Connect electrical connections (6, 7 and 8) at rear automatic air conditioning air recirculation unit (A32/3), install cable tie (5) and clip in retaining clip (1) (see Figure 05.jpg).

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26. Connect refrigerant lines (G and H) to expansion valve.

Important: Replace sealing rings and observe torque of threaded connections (6 Nm).

27. Restore insulation (2) in area of expansion valve and refrigerant lines (G and H).

28. Unscrew protective caps (30 and 31) on test and fi ller connection for high-pressure line (C) and low-pressure li­ne (B) . Connect NC service unit (NC service unit for R134a gotis://E_83_05.0).

29. Evacuate roof NC , fill and check for proper operation and leaktightness.

Note: Observe the previously noted quantity of compressor oil. If the compressor oil quantity is measured incor­rectly , the refrigerant compressor can be damaged.

Information: To do so, note BF83.30-N-1003-01H, BF83.30-N-1001-01H, ASOO.OO-Z-0005-01A.

30. Disconnect NC service unit (NC service unit for R134a gotis://E_83_05.0) and screw the protective caps (30 and 31) onto the testing and filler connections of the high-pressure line (C) and low-pressure line (0) (see Figure 01.jpg).

31 . Replace dust filter of roof air conditioning (see AP83.50-D-8386H).

32. Install center headliner (17) (see Figure 03.jpg and Figure 04.jpg).

33. Install air duct of roof air conditioning (see AR83.50-D-4000-01 B).

34 . Install trim of evaporator unit on inside (see AR83.50-D-5010B).

Attachments

File

01.jpg

02.jpg

03.jpg

04.jpg

05.jpg

06.jpg

07.jpg

08.jpg

09.jpg

10.jpg

Symptoms

Body I Body/Cab I Body sealing I Water entry

Parts

Part number IES1 IES2 I Designation

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Description

Empty/evacuate/refill roof air conditioning and check for proper operation and leaks

Water drain hoses

Center headliner

Center headliner

Rear automatic air conditioning air recirculation unit (A32/ 3) connections

Tightening sequence for rear automatic air conditioning air recirculation unit (A32/3)

Condenser unit

Seal positions on rear automatic air conditioning air recir-culation unit (A32/3)

Rear automatic air conditioning air recirculation unit (A32/ 3) installation

Installation location for timer module

I Quantity I Note

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IEPC IOther

ma-

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A 000 835 22 00 Sealing frame 1

A 013 997 42 45 Sealing ring 1

A 013 997 40 45 Sealing ring 1

A 001 835 87 47 Filter mat 1

A 020 997 76 45 0 -ring 1

A 140 997 06 45 Sealing ring 1

A 001 835 90 47 Desiccant cartridge (observe 1 note)

A 002 835 09 47 Desiccant cartridge (observe 1 note)

A 002 997 24 90 Cable tie 1

A 906 906 33 00 Operating unit 1

Work units

Op. no. Operat ion text Time

83-1770 EMPTY/EVACUATE/REFILL AIR CON-DITIONING SYSTEM, CHECK FOR PROPER OPERATION AND LEAKS (ROOF NC)

83-7199 SEAL AIR RECIRCULATION UNIT OF REAR AIR CONDITIONING (SYSTEM EMPTIED), VEH. WITH ROOF AIR CONDITIONING

83-7201 EXTRA WORK FOR SEALING AIR RE-CIRCULATION UNIT OF REAR AIR CONDITIONING SYSTEM, REPLA-CING OPERATING UNIT VEH. WITH CODE ZU7 I ZU8

WIS-References

Document number Title Note

AS83.00-Z-0001 -01 A

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Risk of explosion from wel-ding or soldering work on the closed air conditioning

RGHAZIZ

ke part

Two-piece seal. x Joint edges not stuck in the area of the radius.

Check via EPC and re-identify x if necessary.

Check via EPC and re-identify x if necessary.

x Check via EPC and re-identify x if necessary.

Check via EPC and re-identify x if necessary.

Up to chassis: E 035949 Up to x date 31 .10.2008 Up to chassis: E 260881 Up to date 11 .01.2008

As of chassis: E 035950 As of x date: 31 .10.2008 As of chassis: E 260882 As of date: 11 .01.2008

x x

Damage Note code

83673 04

83673 04

83673 04

Allocation

Remedy

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system. Risk of poisoning from inhaling overheated refrigerant vapors. Risk of injury from skin and eye contact with liquid refrige-rant

AR83.30-D-1760D Empty/evacuate/refill air Remedy conditioning system and check for proper operation and leaks

AR83.50-D-501 OB Remove/install trim of eva- Remedy porator unit

AR83.50-D-5000B Remove/install trim of con- Remedy denser unit

AR83.50-D-5080B Remove/install fluid reser- Remedy voir of air conditioning (roof equipment)

AR83.50-D-4000-01 B Remove/install air duct of Remedy air conditioning (roof equip-ment)

AH83.30-N-0004-0 1 A Behavior in case of dama- Remedy ged or leaking air conditio-ning system

AH83.30-N-0005-01 A Protect circuit and compo- Remedy nents of air conditioning against moisture during re-pair work

AH83.30-N-0003-01 A Information on handling of Remedy refrigerant R134a

BF83.30-N-1003-01 H Total filling capacity of com- Remedy pressor oil in air conditio-ning system (including refri-gerant compressor)

BF83.30-N-1001 -01 H Total filling capacity, refrige- Remedy rant

ASOO .OO-Z-0005-01 A Risk of accident from the Remedy vehicle moving off by itself when the engine is running. Risk of injury from bruises and burns if you put your hand near engine when it is started or when it is running.

AR68.30-D-4 700A Remove/install trim on B-pil- Remedy lar

AR83.25-D- 1124C Remove/install climate con- Remedy trol control and operating unit

AR68 .1 O-D-1590A Remove/install cover under Remedy steering wheel

I validity

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Vehicle

Sprinter Ill

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