Remove/install the air conditioning's condenser unit (roof equipment)

AR83.50-D-5100A

Remove/install the air conditioning's condenser unit (roof equipment)

06.06.2019

Model

903.66/67, 904.66

with code H08 (Roof-mounted air conditioning system, reinforced)

1

Condenser unit

2

Union nut

3

Connector

4

Union nut

X310b1

High pressure switch

 

Remove/install

 Danger

Risk of death caused by falling from vehicle roof. Risk of injury to other persons caused by falling objects during work in roof area.

Model 903.66 (except 903.662), 903.67, 904.66
with code H08 (Roof-mounted air conditioning system, reinforced)
Model 903.662
with code H08 (Roof-mounted air conditioning system, reinforced)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)

AS65.00-Z-0002-01A

 Danger

Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained.

AS83.00-Z-0001-01A

Topical note

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

Model 903.66 (except 903.662), 903.67, 904.66
with code H08 (Roof-mounted air conditioning system, reinforced)

AH83.30-N-0005-01A

Topical note

Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

1

Drain air conditioning system

AR83.30-D-1760B

2

Remove condenser unit (1) trim from roof

AR83.50-D-5000A

3

Disconnect connector (3) and connector from high-pressure switch (X310b1)

4

Unscrew union nuts (2, 4)



Compressor oils (specification 362.0)

BB00.40-P-0362-00A

 Plug openings.

 Installation: Install new sealing rings. Coat sealing rings with compressor oil before installation.

 Model 903.66 (except 903.663)
with code H08 (Roof-mounted air conditioning system, reinforced)
except code HH6 (Air conditioning, roof equipment)
except code HH7 (Roof-mounted air conditioning system, basic)
except code HK2 (Air conditioning in rear with underfloor condenser)
Model 904.66 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)Line connection, pressure-side refrigerant lines

*BA83.50-N-1016-01B

 Model 903.66 (except 903.663)
with code H08 (Roof-mounted air conditioning system, reinforced)
except code HH6 (Air conditioning, roof equipment)
except code HH7 (Roof-mounted air conditioning system, basic)
except code HK2 (Air conditioning in rear with underfloor condenser)
Model 904.66 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)Line connection, intake-side refrigerant lines

*BA83.50-N-1017-01B

 Record plug

*129589009100

5

Unscrew nuts (arrows) and remove washers

 Model 903.66 (except 903.663)
with code H08 (Roof-mounted air conditioning system, reinforced)
except code HH6 (Air conditioning, roof equipment)
except code HH7 (Roof-mounted air conditioning system, basic)
except code HK2 (Air conditioning in rear with underfloor condenser)
Model 904.66 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)Mounting nut of condenser unit on vehicle roof

*BA83.50-N-1012-01B

6

Cut sealing material on contact surfaces beneath condenser unit (1)

7

Remove condenser unit (1)

 Installation: Determine the amount of compressor oil remaining in the condenser of the removed condenser unit (1). Fill same amount of new compressor oil into condenser of condenser unit (1) to be installed.

 Model 903.661
with code H08 (Roof-mounted air conditioning system, reinforced)
Model 903.662
with code H08 (Roof-mounted air conditioning system, reinforced)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof-mounted air conditioning system, Schrader model 103K
Model 904.66 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)Compressor oil refill quantity when replacing condenser

*BF83.30-N-1003-01A

 Model 903.661
with code H08 (Roof-mounted air conditioning system, reinforced)
Model 903.662
with code H08 (Roof-mounted air conditioning system, reinforced)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof-mounted air conditioning system, Schrader model 103K
Model 904.66 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)Total compressor oil filling capacity for new system (in refrigerant compressor)

*BF83.30-N-1001-01A

 Model 903.661
with code H08 (Roof-mounted air conditioning system, reinforced)
Model 903.662
with code H08 (Roof-mounted air conditioning system, reinforced)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof-mounted air conditioning system, Schrader model 103K
Model 904.66 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)Total compressor oil filling capacity of air conditioning system (including refrigerant compressor)

*BF83.30-N-1011-01A

8

Remove washers from contact surfaces below condenser unit (1)

9

Remove sealant residue down to a 2 mm thick layer

 Installation: Apply new layer of sealing material to contact surfaces.

Terostat 8590

*BR00.45-Z-1041-02A

10

Install in the reverse order

 Mount trim of condenser unit only after filling and checking air conditioning system.

11

Replace air conditioning system filter dryer

AR83.50-D-5090A

12

Evacuate air conditioning system, refill it, and then check the system to make sure that it functions correctly and does not leak

AR83.30-D-1760B

 Rear air conditioning

Number

Designation

Model 903.6 (except 903.663/671/672/673)
with code H08 (Roof-mounted air conditioning system, reinforced)
except code HH6 (Air conditioning, roof equipment)
except code HH7 (Roof-mounted air conditioning system, basic)
except code HK2 (Air conditioning in rear with underfloor condenser)
Model 904.6 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)

BA83.50-N-1012-01B

Mounting nut of condenser unit on vehicle roof

Nm

25

 Rear air conditioning

Number

Designation

Model 903.6 (except 903.663/671/672/673)
with code H08 (Roof-mounted air conditioning system, reinforced)
except code HH6 (Air conditioning, roof equipment)
except code HH7 (Roof-mounted air conditioning system, basic)
except code HK2 (Air conditioning in rear with underfloor condenser)
Model 904.6 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)

BA83.50-N-1016-01B

Line connection, pressure-side refrigerant lines

Nm

35

 Rear air conditioning

Number

Designation

Model 903.6 (except 903.663/671/672/673)
with code H08 (Roof-mounted air conditioning system, reinforced)
except code HH6 (Air conditioning, roof equipment)
except code HH7 (Roof-mounted air conditioning system, basic)
except code HK2 (Air conditioning in rear with underfloor condenser)
Model 904.6 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)

BA83.50-N-1017-01B

Line connection, intake-side refrigerant lines

Nm

35

 Air conditioning

Number

Designation

Model 901.6, 902.6, 904.6 (except 904.663), 905.6 (except 905.613)
with code HH9 (Air conditioner, automatic heater control)
Model 903.661
with code HH9 (Air conditioner, automatic heater control)
Model 903.662
with code HH9 (Air conditioner, automatic heater control)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof air conditioner from Kerstner, type 103K

Model 903.661
with code H08 (Roof-mounted air conditioning system, reinforced)
Model 903.662
with code H08 (Roof-mounted air conditioning system, reinforced)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof air conditioner from Kerstner, type 103K
Model 904.6 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)

BF83.30-N-1001-01A

Total compressor oil filling capacity for new system (in refrigerant compressor)

cm3

–

220

Sheet

-

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

Model 903.661
with code HH6 (Air conditioning, roof equipment)
Model 903.662
with code HH6 (Air conditioning, roof equipment)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof air conditioner from Kerstner, type 103K
Model 903.67, 904.66 (except 904.663)
with code HH6 (Air conditioning, roof equipment)

BF83.30-N-1001-01A

Total compressor oil filling capacity for new system (in refrigerant compressor)

cm3

160

Sheet

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

Model 901.6, 902.6, 904.6 (except 904.663), 905.6 (except 905.613)
with code HH9 (Air conditioner, automatic heater control)
Model 903.661
with code HH9 (Air conditioner, automatic heater control)
Model 903.662
with code HH9 (Air conditioner, automatic heater control)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof air conditioner from Kerstner, type 103K

Model 903.661
with code H08 (Roof-mounted air conditioning system, reinforced)
Model 903.662
with code H08 (Roof-mounted air conditioning system, reinforced)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof air conditioner from Kerstner, type 103K
Model 904.6 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)

BF83.30-N-1003-01A

Compressor oil refill quantity when replacing condenser

cm3

–

20

Sheet

-

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

Model 903.661
with code HH6 (Air conditioning, roof equipment)
Model 903.662
with code HH6 (Air conditioning, roof equipment)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof air conditioner from Kerstner, type 103K
Model 903.67, 904.66 (except 904.663)
with code HH6 (Air conditioning, roof equipment)

BF83.30-N-1003-01A

Compressor oil refill quantity when replacing condenser

cm3

–

Sheet

-

 Air conditioning

Number

Designation

Model 901.6, 902.6, 904.6 (except 904.663), 905.6 (except 905.613)
with code HH9 (Air conditioner, automatic heater control)
Model 903.661
with code HH9 (Air conditioner, automatic heater control)
Model 903.662
with code HH9 (Air conditioner, automatic heater control)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof air conditioner from Kerstner, type 103K

Model 903.661
with code H08 (Roof-mounted air conditioning system, reinforced)
Model 903.662
with code H08 (Roof-mounted air conditioning system, reinforced)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof air conditioner from Kerstner, type 103K
Model 904.6 (except 904.663)
with code H08 (Roof-mounted air conditioning system, reinforced)

BF83.30-N-1011-01A

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

cm3

145

300

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

Model 903.661
with code HH6 (Air conditioning, roof equipment)
Model 903.662
with code HH6 (Air conditioning, roof equipment)
except code Z29 (James Cook touring camper, NAFTA)
except code ZU8 (National version for USA)
Roof air conditioner from Kerstner, type 103K
Model 903.67, 904.66 (except 904.663)
with code HH6 (Air conditioning, roof equipment)

BF83.30-N-1011-01A

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

cm3

410

Sheet

BB00.40-P-0362-00A

Repair materials

Number

Designation

Order number

BR00.45-Z-1041-02A

Terostat 8590

Henkel Teroson GmbH
Hans-Burte-Strasse 4
69123 Heidelberg
Germany
Tel. +49 6221704-0
Fax +49 6221704-698
www.teroson.de