In this video I go through the fuel system, electrical system and test running.
FUEL SYSTEM
In most installs of this type the fuel pump is roughly at the same level as the fuel tank so I personally use normal 4mm fuel hose from the fuel tank to a shut off valve to a fuel filter to the fuel dosing pump. In all cases the dosing pump should be as close to the fuel tank as possible.
From the fuel dosing pump you should only use hard narrow bore fuel hose or tubing. To protect the delivery fuel line and to prevent the dosing pulses being transmitted into the frame of the caravan or motor home, the hard nylon tubing should be inserted in some resilient material such as 6mm or 8mm fuel hose, garden hose or as in this case some vinyl tubing.
In this install I used 6mm bore vinyl tubing just so I could see the fuel dosing bubbles travel along the fuel line as it was a long delivery line and took quite a lot of manual dosing to get the fuel from the pump to the heater. It would take a significant number of aborted starts if you used the heater to prime the system.
There is confusion between what is hose and what is tubing. In general, hose is measured on the inside and is often stated as "nominal bore" This means the bore is approx, not exact along its length. Tubing is measured on the outside and is an exact measurement along its length.
In just about every vehicle install you can not just "T" into the fuel line and must install a separate fuel pick up line or use a separate fuel tank. In many commercial European vehicles they come as standard with a blanked off separate fuel pick up for just this purpose.
In Jens case she had a fuel gauge issue and was advised it was a sender unit that required replacing, and to do this the dealership needed to drop the tank. I suggested to her while the tank was out to have a separate fuel stand pipe installed. The dealership said they did this and charged her $100 on top of the $1,200 for the fuel sender replacement and labour. I thought this was a good price to install a stand pipe. Some months later when I installed the heater I found that this VW Crafter already had a welded in aux fuel pick up fitting so Jen was actually charged just to tag the fitting. After this I tested both the fuel pump and the fuel sender unit in the replaced yellow module (I asked Jen to request the old part.... so I could play with it). I could find nothing wrong here. The fuel pump worked and the gauge sender unit appeared sound. With no manual I did not know the correct readings, but it gave linear ohm readings, as a sender unit should, so I suggested to Jen that I suspected her intermittent fuel gauge issues may not be in the tank sender unit and the problem may lie elsewhere, perhaps lose or corroded wiring or an actual gauge issue in the cab. This proved to be true and the motorhome had to go back to the dealer again at a later date. Jen chose not to claim a refund for the work done previously. She went to a respected dealership, the mechanic was young and inexperienced and perhaps she did not want him to lose his job during these Covid times. I tend to agree, but if it was a sole trader mechanic, I would strongly suggest she seek recourse.
WIRING
All the heaters I have seen come with bare basic wire size. If you extend the wire loom you MUST increase the wire size. In my opinion you should also connect the heater direct to the battery and not to the van distribution box. The heater requires around 10 amps at a minimum of 12 V at the glow plug to start and if you connect to most van distribution boxes you will get excessive voltage drop if the vehicle engine is not running or the solar is not working, The the most likely time you will start the heater is when you are parked up in the evening.
You MUST install a fuse in the power line as close as possible to the battery, and you should install a fuse in the fuel dosing line close to the heater ECU (which sends power to the pump)
I also suggest you install a master heater power shut off switch in a place where it is unlikely to be turned off accidentally.
I hope this video is of some help to the DIY installer.
Warm winter nights. JMcK
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