Retrofit rear air conditioning system

AN83.50-S-0001A

Retrofit rear air conditioning system

24.7.08



Removing

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A



Special instructions for lifting and supporting vehicle

Model 638

AH00.60-N-0100-01A



When working on the refrigerant circuit, seal all openings with suitable caps in order to prevent unnecessary penetration by air humidity and dirt.

All sealing rings must be replaced and wetted using compressor oil.

1.1

Switch vehicle to service mode.

 With air suspension (code CL0).

2

Disconnect ground line of battery



AR54.10-S-0005A

3

Remove front bumper

AR88.20-S-2000A



4

Remove radiator



AR20.20-S-3865D

5

Unscrew clamp (1) for attaching high-pressure line (2) to bracket (3)

6

Unscrew clamp (4) for attaching high-pressure line (2) to transmission

7

Remove high-pressure line (2) from refrigerant compressor (5)

8

Detach suction line (6) from fluid reservoir (7)

9

Remove mounting screws (8) of charge air pipe (9) from axle/engine subframe

10

Unscrew clamp (10) of coolant hose (11) from transmission

11

Unscrew mounting screw (12) of fuel tank (13) from longitudinal member

12

Remove all seats from passenger compartment

 See Operator's Manual

13

Remove inner paneling from left side of load compartment



AR68.30-S-1180B

14

Remove rear headliner



AR68.30-S-7608A

15.1

Unscrew bolts at bracket of backup assist control unit (A35) from body

 With ultrasonic backup assist (code J44).

16.1

Unscrew bolts at bracket (14) of left vent window motor (M2) from body

 With electric rear vent window in passenger compartment (code W32).

17.1

Unscrew left vent window motor mounting screws (M2) from bracket (14)

 With electric rear vent window in passenger compartment (code W32).

18

Remove left taillamp



AR82.10-S-4905A

19.1

Unscrew ALB controller (16) bracket mounting screw (15) from body

 Without ABS (code BB0) or without air suspension (code CL0).

20

Unscrew clamp bracket (18) mounting screw (17) from body

21

Remove front seat

 Driver seat box of LHD vehicle or front passenger seat box of RHD vehicle.



AR91.10-S-1000A

22

Remove lower left clip of cover (19) from
instrument panel (20)

23

Disconnect connections from left rear plastic pocket (21) at instrument panel (20)

24

Remove left front door sill (22)

25

Detach top cover (23) from seat console (24)

 Driver seat box of LHD vehicle or front passenger seat box of RHD vehicle.

26

Remove side paneling (25) from seat console (24)

 Driver seat box of LHD vehicle or front passenger seat box of RHD vehicle.

With code YE2 (refrigerator box) detach connector from cigarette lighter.

27

Release fuse module (26) and put to one side while still connected

 Driver seat box of LHD vehicle or front passenger seat box of RHD vehicle.

28

Put front lining (27) to one side



Install

29

Retrofit bracket for refrigerant lines in engine compartment

AN83.50-S-0001-01A

*BA83.50-N-1010-01A

*BA83.50-N-1011-01A

*BA83.50-N-1012-01A

*BA83.50-N-1013-01A

30

Retrofit refrigerant line brackets to body

AN83.50-S-0001-02A



*BA42.20-N-1010-01B



*BA42.80-N-1002-01A



*BA47.10-N-1001-01A



*BA83.50-N-1014-01A



*BA83.50-N-1015-01A

31

Subsequently fabricate refrigerant line leadthrough in floor area

AN83.50-S-0001-03A

32

Fit refrigerant lines

AN83.50-S-0001-04A



*BA83.30-N-1003-01A



*BA83.50-N-1001-01A



*BA83.50-N-1002-01A



*BA83.50-N-1007-01A



*BA83.50-N-1008-01A



*BA83.50-N-1009-01A



*BA83.55-N-1002-01A

33

Install radiator

 Do not fill air conditioning system.



AR20.20-S-3865D

34

Install front bumper



AR88.20-S-2000A

35.1

Subsequently reposition bracket with backup assist control unit (A35)

 With ultrasonic backup assist (code J44).

AN83.50-S-0001-05A

36.1

Subsequently reposition bracket with left vent window motor (M2)

 With electric rear vent window in passenger compartment (code W32).

AN83.50-S-0001-06A

37

Retrofit rear air conditioner housing

AN83.50-S-0001-07A



*BA83.50-N-1003-01A



*BA83.50-N-1004-01A



*BA83.50-N-1005-01A

38

Retrofit rear air conditioning system wiring harness

AN83.50-S-0001-08A

 Wiring harness repair kit

*220589019900

39

Install left taillamp



AR82.10-S-4905A

40

Fit side paneling (25) to seat console (24)

 Driver seat box of LHD vehicle or front passenger seat box of RHD vehicle.

With code YE2 (refrigerator box) attach connector to cigarette lighter.

41

Fit top cover (23) to seat console (24)

 Driver seat box of LHD vehicle or front passenger seat box of RHD vehicle.

42

Install left front door sill (22)

43

Install left plastic pocket (21) below instrument panel (20)

 Replace cable ties.

44

Fit lower left clip of cover (19) to
instrument panel (20)

45

Subsequently make cutouts in rear headliner

AN83.50-S-0001-09A

46

Install rear headliner

 Do not install top left luggage net bracket, use screw (28) with a suitable U-washer (29) in its place.

Do not install interior trim at left D-pillar on left side of load compartment.



AR68.30-S-7608A

47

Retrofit air duct bracket

AN83.50-S-0001-10A



*BA83.50-N-1016-01A

48

Retrofit air ducts

AN83.50-S-0001-11A

49

Subsequently fabricate cutout in left load compartment interior trim

AN83.50-S-0001-12A

50

Clean vehicle interior

51

Install front seat

 Driver seat box of LHD vehicle or front passenger seat box of RHD vehicle.



AR91.10-S-1000A

52

Install all seats in passenger compartment

 See Operator's Manual

53

Fill air conditioning system



AR83.30-S-1760A

54

Affix new sticker (30) showing refrigerant charge to lock crossmember (31)

55

Connect ground cable to battery



AR54.10-S-0005A



Checking

56

Read out fault memory with HHT/Star Diagnosis and erase.

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury from crush injuries and burns if you place your hand into the engine when it is started or when it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

57

Check air conditioning for proper operation

 Run engine at idling speed for about 4 minutes and check all the component functions which are of relevance for proper operation of the air conditioning system.

Number

Designation

Model
638

BA42.20-N-1010-01B

Bolt/nut, adjusting stirrup bracket to body

Nm

29

Number

Designation

Model
638 without
Code BB0

BA42.80-N-1002-01A

Bolt, ALB controller to body

M8

Nm

24

Number

Designation

Model
638

BA47.10-N-1001-01A

Clamp attaching fuel tank to longitudinal member

Nm

28

Number

Designation

Model
638

BA83.30-N-1003-01A

High pressure lines to fluid reservoir

Nm

17

Number

Designation

Model 638 with code H06 and HH7

BA83.50-N-1001-01A

Connection fitting of rear high-pressure line of rear air conditioning to front high-pressure line of rear air conditioning

Nm

17

BA83.50-N-1002-01A

Connection fitting of rear suction line of rear air conditioning to front suction line of rear air conditioning

Nm

27

BA83.50-N-1003-01A

Nut for rear suction and high pressure line to rear air conditioner housing

Nm

10

BA83.50-N-1004-01A

Bolt for rear air conditioner housing bracket

M6

Nm

10

M8

Nm

18

BA83.50-N-1005-01A

Bolt for rear air conditioner housing bracket to body

Nm

6

BA83.50-N-1007-01A

Bolt for dual hose clamp of tubing harness of rear air conditioning to bracket

Nm

3

BA83.50-N-1008-01A

Bolt for hose clamp of tubing harness of rear air conditioning to bracket

Nm

5

BA83.50-N-1009-01A

Bolt with nut of dual hose clamp of tubing harness of rear air conditioning

Nm

3

BA83.50-N-1010-01A

Bolt of bracket to bracket of oil pan

Nm

10

BA83.50-N-1011-01A

Bolt, high-pressure center line clamp with bracket to transmission

Nm

5

BA83.50-N-1012-01A

Bolt, coolant hose clamp with bracket to transmission

Nm

22

BA83.50-N-1013-01A

Nut, bracket to charge air pipe

Nm

22

BA83.50-N-1014-01A

Bolt, bracket to axle/engine subframe

Nm

10

BA83.50-N-1015-01A

Bolt, bracket to body

Nm

10

BA83.50-N-1016-01A

Bolt, air duct bracket to body

Nm

10

Number

Designation

Model
638 with engine 611.980 without H06,
HH7

BA83.55-N-1002-01A

Bolt of suction and high pressure line to refrigerant compressor

Nm

16

Part no.

Designation

Quantity

000 540 84 05

Cable set

1

000 692 00 00 - 7C65

Evaporator cover, aerogray

1

000 692 00 00 - 8H43

Evaporator cover, mushroom

1

000 692 00 98

Edge stripping, black (638.2)

1

000 830 07 14

Aluminum profiles

4

000 830 08 14

Basic bracket kit

1

000 830 08 30

Rubber boot

1

000 830 09 14

Air conditioner housing bracket (top)

1

000 830 09 30 - 8H43

Rising duct, mushroom, flock-coated

1

000 830 09 30 - 7C65

Rising duct, aerogray, flock-coated

1

000 830 10 14

Rear air conditioner housing bracket (center)

1

000 830 10 30 - 8H43

Cross duct, mushroom, flock-coated

1

000 830 10 30 - 7C65

Cross duct, aerogray, flock-coated

1

000 830 11 14

Rear air conditioner housing bracket (bottom)

1

000 830 12 14

Air duct bracket (29 mm rear)

1

000 830 13 14

Vent window bracket

1

000 830 14 14

Air duct bracket (37 mm front)

2

000 830 21 14

Bracket at charge air pipe (engine 611)

1

000 830 22 14

Small bracket at transmission (engine 611)

1

000 830 23 14

Large bracket at transmission (engine 611)

1

000 830 24 14

Bracket at oil pan bracket (engine 611)

1

000 830 32 18

Intake opening, black

1

000 831 02 95

Rubber grommet

1

000 831 15 28

Intermediate piece

1

000 832 06 05

Rear high-pressure line of rear air conditioning system (basic)

1

000 832 07 05

Rear suction line of rear air conditioning system (basic)

1

000 832 08 05

Front suction line of rear air conditioning system (engine 611)

1

000 832 09 05

Front high-pressure line of rear air conditioning system (engine 611)

1

000 835 00 27

Four-pin connector

1

000 987 05 64

Gasket

1

001 821 24 25

Blower switch connector

1

001 835 40 98

Gasket

1

001 990 80 50

Nut for blower switch

1

002 545 12 01

Fuse strip (F28-36)

1

002 997 05 68

Y-fitting

1

003 997 46 86 - 8H43

Plastic cover, mushroom, flock-coated

2

003 997 46 86 - 7C65

Plastic cover, aerogray, flock-coated

2

028 997 68 48

O-ring (17 x 2.0)

1

028 997 69 48

O-ring (7.5 x 2.0)

1

028 997 70 48

O-ring (14 x 2.5)

1

028 997 71 48

O-ring (7.65 x 1.78)

1

028 997 72 48

O-ring (24 x 2.5)

1

028 997 73 48

O-ring (9.5 x 2.5)

1

N 072 581 00 03 03

Fuse 7.5A

1

N 072 581 00 03 05

15A fuse

1

163 820 00 92

Rotary knob

1

638 830 02 30 - 8H43

Center duct, mushroom, flock-coated

1

638 830 02 30 - 7C65

Center duct, aerogray, flock-coated

1

638 830 10 08

Air vent

4

638 830 20 61

Rear air conditioner housing

1

638 833 00 27

Number ring

1

638 995 04 44

Dual hose clamp

10

667 545 01 04

Blower switch

1

N 916 016 01 82 02

Hose clamp 18 mm

4

N 916 016 02 82 04

Hose clamp 28 mm

4