Time to remove the roof AC unit. The roof top AC unit is engine powered by its own compressor and designed to keep the interior cool when loaded with passengers. Unfortunately the unit eats a lot of valuable roof top space that for us could be better used for roof racks, solar panels, vents etc. Since spring we have put almost 12k miles on the van and tested it in temperatures up past 100 deg, in all but the hottest temps we found the dash AC proved to be sufficient and it should be even better once the van is fully insulated. For now I'll be installing a couple Maxair Fans on the roof, solar panels and insulation, eventually I'll add a roof rack down the road as well.
Supplies that I used:
- Astro rubber eraser tool - Available on Amazon Here: CLICK HERE
- 3M Panel Bond Adhesive 08115 - Available on Amazon Here: CLICK HERE
- Sikaflex 252 Sealant - Available on Amazon Here: CLICK HERE
- Maxxfan Deluxe - Available on Amazon Here: CLICK HERE
- Dicor Lap Sealant x two tubes- Available on Amazon Here: CLICK HERE
- Nitrile Gloves - Available on Amazon Here: CLICK HERE
- Wax/Degreaser - Available on Amazon Here: CLICK HERE
- Raptor Liner - Available on Amazon Here: CLICK HERE
First up remove the interior in preparation for AC removal and insulation. Start at the front and work your way to the back of the van. I didn't take pictures of the removal process but do have before and after shots.
And after headliner removal.
Removing the side panels. The trim around the windows can stay in place since insulation can be pushed up into the open areas with the trim in place.
Pile of interior parts
Next up is to remove the upper AC unit from the roof. First up take your van to a shop that can reclaim/drain the refrigerant in the upper AC unit, once the unit is drained of refrigerant your ready to start the removal process.
With winter setting in I ran the van over to my buddy Mike's at VanLab to put the van in his nice heated shop....thanks Mike.
In the next couple shots I've already completed a lot of the smaller prep work. At this point you should remove the interior refrigerant lines from the AC unit, the lines run from the unit then down the A pillars. You will need to remove the plastic A pillar trim from both the drivers and passengers side so you can remove the AC lines from the interior of the van. There are two condensate drain lines that get removed at this time as well. Disconnect all the electrical connectors at the AC unit at this time.
Here you can see where I disconnected one of the two AC lines that go through the roof. Next remove the 10mm bolts that attach the upper unit to the roof, there are two 10mm bolts at each AC line connection.
Next move to the roof and remove the bolts from the plastic covers.
Remove the rear plastic cover. Note: The front cover is trapped in place until you remove the rear condenser unit.
In this shot you can see how the condenser unit is attached to the van with 6 studs. The nuts and washers you need to remove are buried under a bunch of white sealant (Looks like Sikaflex).