LI83.50-N-059306 Service Bulletin/Repair Instructions

ENTRY
Water ingress into vehicle interior via roof air conditioning

Topic number
Ll83.50-N-059306
Version
4
Design group
83.50 Rear air conditioning
Date
11-13-2014
Validity
MODEL 906.6/7## #S up to 908728 with CODE HOB

(High-performance air conditioning in passenger compartment)

MODEL 906.6/7## #S up to 908728 with CODE HHO (Ai

C system parts kit) and with CODE HH5 (A/C system

preinstallation)
Reason for change
Validity adjusted, replacement part number of operating

unit added/ adjusted
Reason for block
Complaint:

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

Water enters between the evaporator unit and the vehicle roof.

Condensation enters due to unfavorable pressure ratios.
Remedy:

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

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

Note: Protect circuit 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 A/C service unit (A/C service unit for R134a gotis://

E_83_05.0) (see Figure 01.jpg) and extract refrigerant; the quantity of compressor oil extracted must be noted

down.
2.
Disconnect A/C service unit (A/C 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 (D) (see Figure

01.jpg).
3.
Check whether a timer module has been installed.

Note: 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 1O.jpg).

If yes, create a PTSS case for further assistance.
4.
Replace AAC [KLA] control and operating unit ($98) (see AR83.25-D-1124C).
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5.
Remove trim of evaporator unit on inside (see AR83.50-D-5010B).
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 D03 (High roof), CODE T16 (Right sliding

door) and CODE FY1 (Interior protection).

Note: To do this, 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). Unclip clip (19) of front headliner (16) at the

rear. Remove expansion rivets (18) of center headliner (17) at the front. Unclip clip (22) of center headliner (17)

at the rear and in the vicinity of the evaporator unit. Remove expansion rivet (15) on C-pillar 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).

Note: 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 slop 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), disconnecl 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 bolls 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 (11). 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 untt (A32/3) with

approved MB cleaning agents.

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

16.
Replace sealing 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 aligned 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 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.
18.
Install installajjon 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 fluid reservoir (see AR83.50-D-5080B).

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.
20.
Install strut (11 ). 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 grille (12) and right air grille (10) (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.
21.
Install outer trim on 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.
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.
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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).
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 filler connection for high-pressure line (C) and low-pressure line (B). Connect A/C service unit (A/C service unit for R134a gotis://E_83_05.0).
29.
Evacuate roof A/C, 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.

Note: Observe BF83.30-N-1003-01H, BF83.30-N-1001-01H, AS00.00-Z-0005-01A.
30.
Disconnect A/C service unit (A/C 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 (D) (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
Description
01.jpg
Empty/evacuate/refill roof air conditioning and check for

proper operation and leaks
02jpg
Water drain hoses
03.jpg
Center headliner
04.jpg
Center headliner
05.jpg
Rear automatic air conditioning air recirculation unit (A32/

3) connections
06.jpg
Tightening sequence for rear automatic air conditioning

air recirculation unit (A32/3)
07.jpg
Condenser unit
08.jpg
Seal positions on rear automatic air conditioning air recirculation unit (A32/3)
09.jpg
Rear automatic air conditioning air recirculation unit (A32/

3) installation
10.jpg
Installation location for timer module
Symptoms

Body I Body/Cab I Body sealing I Water entry
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Parts

Part number
ES1 ES2
Designation
Quantity Note
A 000 835 22 00
Sealing frame
1
Two-piece seal.

Joint edges not stuck in the area of

the radius.
x
A 013 997 42 45

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