Remove/install hot water boiler

AR86.30-D-0050EC

Remove/install hot water boiler

30.05.2016

Model

903.6

with code ZL9 (James Cook touring camper)

1

Bolts

3

Ventilation

24

Screw

2

Seal

5

Flap

25

Flap

4

Tarpaulin

6

Main shutoff valve

7

Hot water boiler shut-off valve

8

Gas cooker shut-off valve

9

Nut

13

Gas line

10

Nuts

15

Electrical connector

19

Electrical connector

11

Gas line elbow

16

Bolts

21

Washer

12

Angles

17

Cover

A99

Hot water boiler

14

Shelf

18

Cable tie

20

Bolts

26

Flap

22

Hoses

23

Hose clamps

A99

Hot water boiler

 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 fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A



Notes on carrying out repair work in the vehicle interior

AH68.00-N-0001-01S

 

Remove/install

1

Drain hot water boiler (A99)

 See Owner's Manual.

2

Open flap (25)

3

Connect safety bottle valve to gas cylinder

 See Owner's Manual.

4

Remove grate for wall chimney of hot water boiler (A99)

AR88.00-D-1400EC

5

Remove sealing seam (2) from ventilation (3)

 Remove residues of seam sealing (2) with suitable cleaner.

 Installation: Use white sealant on vehicles painted in white. Smooth sealing seam (2) with suitable tool if applicable.

 Installation: Use black sealant on vehicles which are not painted white. Smooth sealing seam (2) with suitable tool if applicable.

White sealing compound, 310 ml, DBL 6069.20

*BR00.45-Z-1003-01A

Sealant, black

*BR00.45-Z-1099-01A

6

Remove bolt (1)

7

Remove screw/bolt (24)

8

Open wardrobe flap (5)

9

Remove tarp (4)

10

Close main shut-off valve (6)

 See Owner's Manual.

11

Remove hot water boiler shut-off valve (7)

 See Owner's Manual.

12

Close gas cooker shut-off valve (8)

 See Owner's Manual.

13

Unscrew nut (9) from hot water boiler shut-off valve (7)

14

Remove sanitary block mirror

AR86.30-D-0081EC

15

Unscrew nuts (10)

16

Remove gas line elbow (11)

17

Slide bracket (12) with gas line (13) downward


The angle piece (12) must be flush with the floor (14).
Otherwise, when removing and installing the hot water boiler (A99) the hot water boiler (A99) can be removed.

18

Remove cable ties (18)

 Installation: Use new cable ties (18).

19

Disconnect electrical connection (15)

20

Remove bolt (16)

21

Remove cover (17)

22

Disconnect electrical connection (19)

23

Open flap (26)

24

Unscrew screws/bolts (20)

 Installation: Tighten bolts (20) together with bolts (1) and bolt (24).

25

Slightly pull out hot water boiler (A99), turn 90° and lay down

 Installation:
Install shim (21) below left foot of hot water boiler (A99).
Otherwise it is not ensured that the hot water boiler (A99) is installed correctly and the hot water boiler (A99) can be damaged.

26

Detach hoses (22)

27

Remove hot water boiler (A99)

28

Mark installation position of hoses (22) on hot water boiler (A99)

29

Loosen hose clamps (23)

30

Detach hoses (22)

31

Remove hot water boiler (A99)

 Installation: Helper required to align hot water boiler (A99) and to position bolts (1, 20, 24).

32

Check hose clamps (23) and hoses (22) for damage, replace if necessary

33

Install in the reverse order

34

Check gas system for leakage

 It is necessary that the leaktightness and function test is performed and documented by an authorized specialist after opening the gas system.

35

Fill hot water boiler (A99)

 See Owner's Manual.

Repair materials

Number

Designation

Order number

BR00.45-Z-1003-01A

White sealing compound, 310 ml, DBL 6069.20

A 001 989 63 20

BR00.45-Z-1099-01A

Sealant, black

A 001 989 64 20 9120