Remove/install hot water boiler

AR86.30-D-0050A

Remove/install hot water boiler

30.05.2016

Model

903.662

with code Z29 (James Cook touring camper, NAFTA)

with code ZU8 (National version for USA)

1

Hot water boiler

4

Water lines

7

Bolts

2

Screw

5

Tensioning strap

8

Gas line

3

Vent hose

6

Outside flap

9

Cover frame

 Danger !

Risk of explosion due to escaping combustible gas or overheating of gas cylinders.Risk of injury caused by burns to skin and eyes. Risk of frostbite to body parts caused by escaping gas and by touching components near the valves when emptying gas cylinders. Risk of poisoning or suffocation caused by inhaling gas.

Remove any sources of ignition.
Protective clothing, safety gloves and safety glasses must always be worn.
Ensure that the work area is adequately ventilated.
When working on vehicles at ambient temperatures over 60 °C, all gas cylinders must be removed.

AS00.00-Z-0018-01A

 Danger !

Risk of injury caused by hot water exiting from the lines of the fresh water system

Shut off water heater in a timely manner before starting repair work. Let the water in the line system and all components of the fresh water system lines cool down to ambient temperature.

AS86.00-Z-0002-01A

 Danger !

Risk of injury caused by body parts becoming jammed, pinched or severed by doors, covers, flaps or by loose components

Keep body parts well away from moving doors, covers, flaps and components. Wear protective gloves and work shoes.

AS00.00-Z-0025-01A

 Danger !

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01B

 

Remove/install

1

Switch off hot water boiler (1)

 See owner's manual.

2

Drain hot water boiler (1)

AR86.30-D-0051A

3

Close main shut-off valve of gas system on gas reservoir

 See owner's manual.

4

Remove screw/bolt (2)

5

Remove bleed hose (3) from power supply unit

 Only in area of hot water boiler (1).

6

Loosen hose clamps on water lines (4)

7

Mark installation position of water lines (4) on hot water boiler (1)

8

Remove water lines (4) from hot water boiler (1)

9

Loosen tensioning strap (5)

10

Remove outer flap (6) from hot water boiler (1)

AR86.30-D-0052A

11

Remove screws/bolts (7)

12

Disconnect gas line (8) from hot water boiler (1)

13

Remove hot water boiler (1)


Carefully pull hot water boiler (1) out of side wall.
Otherwise the insulation of the hot water boiler (1) can be damaged.

 Installation: Apply new sealant to rear of cover frame (9).

14

Install in the reverse order

15

Check gas system for leakage

AR86.60-D-0100A

16

Carry out function check

 Switch on hot water boiler (1) and check heat output.

17

Glue safety sticker to hot water boiler (1)

Only when replacing hot water boiler (1).