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Water entry into vehicle interior through roof air conditioner (H08)
Topic number

Ll83.50-N-059306

Version
Design group

83.50 Rear air conditioning

Date

07-08-2014

Validity

TYP 906.6/7 with CODE HOB

Reason for change
Reason for block

Complaint
Water entry into vehicle interior through roof air conditioner (HOB).

Cause:
Water entry between evaporator unit and vehicle roof. Entry of condensation due to unfavorable pressure conditions.

Remedy:
1. Drain roof air conditioner. The following safety information and notes must be observed: ASB3.00-Z-0001-01A,
AHB3.30-N-0004-01A, AHB3.30-N-0003-01A.
Note: Protect air conditioning circuit and components from moisture when carrying out repair work.
Note: The test and filler connections of the refrigerant circuit of the roof air conditioner are located on the right of the
longitudinal member in the engine compartment (viewed in direction of travel) (see picture 01.jpg).
Info: To do so, unscrew the protective caps (30 and 31) on the test and filler connection of the high-pressure line (C)
and low-pressure line (D) (see picture 01.jpg). Connect AC service unit (R134a AC service unit, gotis://E_B3_05.0)
(see picture 01.jpg) and extract refrigerant. Note down the quantity of compressor oil extracted.
2. Disconnect AC service unit (R134a AC service unit, gotis://E_B3_05.0) and screw on protective caps (30 and 31) on
test and filler connection of high-pressure line (C) and low-pressure line (D) (see picture 01.jpg).
3. Remove interior cover of evaporator unit (see ARB3.50-D-5010B).
4. Remove air duct of air conditioning (roof equipment) (see ARB3.50-D-4000-01 B).
5. Replace MC control and operating unit (S9B) (see AR83.25-D-1124C).
6. Remove center headliner (17) (see picture 03.jpg and picture 04.jpg).
Note: Picture and information illustrate/describe vehicle with CODE D03 (High roof), CODE T16 (Right sliding door)
and CODE FY1 (Interior protection).
Info: To do so, unclip interior sensor (M) and disconnect electrical connector. Partially unclip B-pillar trim on driver side
and passenger side (21 and 20) in upper area (see AR6B.30-D-4700A). Unclip clips (19) of front headliner (16) in rear
area. Remove expansion rivets (1B) of center headliner (17) in front area. Unclip clips (22) of center headliner (17) in
rear area and in area of evaporator unit. Remove expansion rivet (15) on passenger-side C-pillar. In order to unhook
the center headliner (17) from the body a~d remove it, press the center headliner (17) upwards with a plastic wedge
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and pull it slightly inwards in the process. This should be done on the left (viewed in direction of travel) between each
of the cutouts of the center headliner (17) (see picture 04.jpg (green arrows).
7. Remove refrigerant lines (G and H) from expansion valve (see picture 05.jpg).
Info: To do so, remove insulation (2) in connection area of refrigerant lines (G and H). Remove nuts (3 and 4) and detach refrigerant lines (G and H) from expansion valve.
Important: Seal the openings on the expansion valve and on the refrigerant lines (G and H) with stop plugs (W129
589 00 91 00), otherwise damage can be caused by moisture entering.
8. Unclip clips (K) which attach condensation hose (F) to rear MC air recirculation unit (A32/3) and disconnect condensation hoses (F and E) from rear MC air recirculation unit {A32/3) (see picture 05.jpg).
9. Remove cable ties (5), disconnect electrical connectors (6, 7 and 8) on rear MC air recirculation unit {A32/3) and
unclip retaining clip (1) (see picture 05.jpg).
10. Remove mounting screws/bolts of rear MC air recirculation unit (A32/3) and remove frame (see picture 06.jpg).
11. Remove outer cover on condenser unit (see AR83.50-D-5000B).
Warning: Use a suitable working platform for the specified work. If persons or materials fall from the vehicle roof, there
is a risk of injury or even death.
12. Remove left (12) and right (10) air grilles. Unscrew nut (14) of refrigerant line (9) on strut (11 ). Remove screws/
bolts (13) on left and right of strut (11). Remove strut (11) (see picture 07.jpg).
Warning: Use a suitable working platform for the specified work. If persons or materials fall from the vehicle roof, there
is a risk of injury or even death.
13. Remove rear MC air recirculation unit (A32/3). Info: Have a second person help you.
Warning: Use a suitable working platform for the specified work. If persons or materials fall from the vehicle roof, there
is a risk of injury or even death.
14. Clean roof panel in area of contact surface of rear MC air recirculation unit (A32/3) with approved MB cleaning
agents. Important: The surface of the sealing area must be clean and free of grease.
Warning: Use a suitable working platform for the specified work. If persons or materials fall from the vehicle roof, there
is a risk of injury or even death.
15. Replace sealing frame (23) on rear MC air recirculation unit (A32/3) (see picture 08.jpg) (only use the specified
part number).
Info: To do so, remove the old sealing frame (23) and clean bonding area for new sealing frame (23) on rear MC air
recirculation unit (A32/3). Start by bonding the shorter sealing frame section (23) at the position indicated (see red
arrow) (see picture 08.jpg). Only remove as much protective foil of the sealing frame (23) as can be stuck on in one
go. Make sure you avoid getting the adhesive side of the sealing frame (23) dirty. The joints of the sealing frame (23)
must not be in the radius area. The sealing frame (23) must not be separated from/have a gap (26) between the end
stop/edge (see picture 08.jpg).
If the sealing frame (23) is too long, the joint must be shortened accordingly to match the original L-shape.
Note: Stick on sealing frame (23) without tension otherwise the sealing cross-section is reduced.
16. Insert rear MC air recirculation unit {A32/3) in vehicle roof and align (see picture 09.jpg).
Info: The rear MC air recirculation unit (A32/3) is aligned based on the end stops (27 and 28) (in direction of travel)
and end stop (29) (passenger-side). These must contact the roof cutout (see picture 09.jpg).
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Warning: Use a suitable working platform for the specified work. If persons or materials fall from the vehicle roof, there
is a risk of injury or even death.
17. Install installation frame (see picture 06.jpg). Important: Make sure you observe the torque (4 Nm) and tightening
sequence (see picture 06.jpg), arrow (blue) indicates direction of travel.
18. Replace fluid reservoir (see AR83.50-D-5080B).
Warning: Use a suitable working platform for the specified work. If persons or materials fall from the vehicle roof, there
is a risk of injury or even death.

19. Install strut (11). Tighten screws/bolts (13) on left and right of strut (11) to specified torque (13.5 Nm). Screw on
nut (14) of refrigerant line (9) on strut (11). Install left air grille (12) and right air grille (10) (see picture 07.jpg).
Warning: Use a suitable working platform for the specified work. If persons or materials fall from the vehicle roof, there
is a risk of injury or even death.
20. Install outer cover on condenser unit (see AR83.50-D-5000B).

Warning: Use a suitable working platform for the specified work. If persons or materials fall from the vehicle roof, there
is a risk of injury or even death.
21. Install condensation hoses (E and F) on rear AAC air recirculation unit (A32/3) (see picture 05.jpg).
22. Check drain hoses for condensation for unobstructed flow (see picture 02.jpg).
Info: To do so, introduce water through the opening on the filter of the rear AAC air recirculation unit (A32/3) with a hose (34). Water must be seen exiting the outlet points (32 and 33) of the condensation hoses, otherwise the water drainage system must be reworked.
23. Perform a rain test for a period of at least 1Ominutes.
Note: If water again enters the vehicle interior, create a TIPS case to clarify the further procedure.
24. Connect electrical connectors (6, 7 and 8) on rear AAC air recirculation unit (A32/3), fit cable ties (5) and clip in retaining clip (1) (see picture 05.jpg).
25. Install refrigerant lines (G and H) on expansion valve. Important: Replace sealing rings and observe torque of
threaded connections (6 Nm).
26. Refit insulation (2) in area of expansion valve and refrigerant lines (G and H).
27. Remove protective caps (30 and 31) on test and filler connection of high-pressure line (C) and low-pressure line
(B). Connect AC service unit (R134a AC service unit, gotis://E_83_05.0).
28. Evacuate the roof air conditioner, fill it and then check for proper operation and leaks.
Note: Observe the compressor oil quantity noted down earlier. If the quantity of compressor oil is measured incorrectly, the refrigerant compressor can be damaged.
Info: Observe BF83.30-N-1003-01 H, BF83.30-N-1001-01 H, AS00.00-Z-0005-01A.
29. Disconnect AC service unit (R134a AC service unit, gotis://E_83_05.Q) and screw on protective caps (30 and 31)
on test and filler connection of high-pressure line (C) and low-pressure line (D) (see picture 01.jpg).
30. Replace dust filter of roof air conditioner (see AP83.50-D-8386H).
31. Install center headliner (17) (see picture 03.jpg and picture 04.jpg).

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32. Install air duct of roof air conditioner (see AR83.50-D-4000-01 B). 33. Install interior cover of evaporator unit (see
AR83.50-D-5010B).

Attachments
File

Description

01.jpg

Drain roof air conditioning, evacuate and recharge the system and check for operation and leaks

02.jpg

Water drain hoses

03.jpg

Center headliner

04.jpg

Center headliner

05.jpg

Air circulation unit (A32 I 3) Connections

06.jpg

Remove mounting screws/bolts of rear Air circulation unit
(A32/3)

07.jpg

Condenser Unit

08.jpg

Install seal for the Air circulation unit (A32/3)

09.jpg

Reinstall Air circulation unit (A32/3)

Symptoms
Body I Body/Cab I Body sealing I Water entry

Parts
Part number

ES1 ES2

Designation

Quantity Note

A 000 835 22 00

Sealing Frame (Bottom)

1

Two-piece seal.
Bond the edges of the seal on
the straight edge of housing.

x

A 013 997 42 45

Sealing Ring

1

Check EPC

A013 997 4045

Sealing Ring

1

Check EPC

A 001 835 87 47

Filter Mat

1

A 020 997 76 45

0-Ring

1

x
x
x
x
x
x

Check EPC

A 140 997 06 45

Sealing Ring

1

A 001 835 90 47

Dryer Cartridge

1

Up to VIN: E 035949 date: 10/
31/2008
Up to VIN: S 260881 date: 01/
11/2008

A 002 835 09 47

Drying Insert

1

From VIN: E 035950 date: 10/
31/2008
From VIN: S 260882 date: 01/
11/2008

A 002 997 24 90

Cable Tie

1

A 906 906 33 00

Operating Unit

1

EPC Other
make
part

x
x
x

Work units
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Op. no.

Operation text

83-1770

DRAIN, EVACUATE AND REFILL A/C
SYSTEM FOR PROPER OPERATION
AND LEAKS (ROOF AIR CONDITIONING)

Time

Damage
code

Note

83673 04

WIS-References
Document number

Tille

AS83.00-Z-0001-01A

Risk of explosion caused by
welding or soldering work
on closed air conditioning
system. Risk of poisoning
cuased by inhaling overhea-

Note

Allocation
Remedy

ted refirgerant vapors. Risk

of injury to skin and eyes
caused by contact with Iiquid refrigerant.
AR83.30-D-1760D

Drain, evacuate, and recharge air conditioning, check
for proper operation and
check for leaks

Remedy

AR83.50-D-5010B

Remove/install evaporate
unit paneling

Remedy

AR83.50-D-5000B

Remove/install condenser
unit paneling

Remedy

AR83.50-D-5080B

Remove/install the air
contitioning's fluid reservoir
(roof equipment)

Remedy

AR83.50-D-4000-01 B

Remove/install the air duct
for the air conditioning (roof
equipment)

Remedy

AH83.30-N-0004-01A

Procedure for a damaged
or leaky air conditioning system

Remedy

AH83.30-N-0005-01 A

Protect air conditioning circuit and components from
moisture when carrying out
repair work

Remedy

AH83.30-N-0003-01 A

Notes on handling refigerant
R134a

Remedy

BF83.30-N-1003-01 H

Total compressor oil filling
capacity of air conditioning
system (including AC compresser)

Remedy

BF83.30-N-1001-01 H

Total filling capacity, refrigerant

Remedy

ASOO.OO-Z-0005-01 A

Risk of accident from vehicle starting off by itself when
engine running. Risk of injury (bruises and burns) resul-

Remedy

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ting from working on the engine while it is being started

or when it is running.
AR68.30-D-4700A

Remove/install paneling on
B-pillar

Remedy

AR83.25-D-1124C

Remove and install air conditioning control and operating unit

Remedy

Validity
Vehicle

Engine

Transmission

Sprinter Ill

•

•

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