Espar D5 Heater Install - Lots of Pics - Part 2

[Ahab]

Part 2 of the Espar Heater Install.

I then installed the controller in the suggested location, using the supplied template. Two holes have to be drilled, then pins inserted into connectors, then just simply hooked up. The wiring was then tied up, out of the way under the dash.


The wiring for the blower motor was run to the drivers side and connected to one of the connectors just run into the cab. Here is the blower motor connector.


Lastly, I worked on running the fuel supply, which I was most worried about. I wasn't sure if I needed to drop the tank, but it turned out that I did not. There was enough room to reach up inbetween the fuel tank and drive shaft to disconnect the fuel return connector, shown below.
It just requires squeezing the connector while pulling on the line.


You then have to remove the grey quick-connect connector and move it to the supplied "Y" connector.
I then ran the hard fuel line from the heater to the top of the fuel tank to the sending unit, cutting to length. Then inserting it into the brass compression fitting and tightening.
Then you attach the Y connector to the nipple on the sending unit, then attach the factory return line to the bottom of the Y connector. Make SURE that the connectors are fully connected and locked on fully.

Almost complete!! Thanks for hanging in there!

Lastly, I connected the power directly to the battery terminals. The wires have ring connectors on both the positive and negative leads.

To fire the unit up, you first have to set the time on the controller, then you just press the "heat" button and let it prime itself, which can take a few tries, then let it run for a bit. I needed to add approximately 1/2 liter of mixed coolant to the overflow tank due to the filling of the hose going to the heater.

Once the unit is running, it kind of sounds like a small jet engine, or a little boiler I guess. Not loud, but not quiet either.

A couple of facts that I found out so far about the general operation of the Espar D5 coolant heater.

1) The mini controller only allows for 3 timed operations per 24hr period, and only allows for a max running time of 2hrs per operation - ie you can only program it to run automatically for 6 hrs per day using the timer.

2) With the unit drawing fuel from the fuel return line, you cannot empty the tank if you force the unit to run continuous - this is a good thing! Leaves you with a 1/4 tank - according to technician at Espar.

3) It seems that the unit does not get the coolant hot enough to open the thermostat, therefore, when you fire the engine up it will get slugged with the cold coolant trapped in the radiator once the thermostat finally opens.

4) The blower relay only supplies power to the blower motor, it does NOT power the mode door. So you need to make sure the mode is correct before shutting down the truck. ie - full defrost, or full heat, etc.

I will add more points as I discover them.

Thanks for reading, sorry for the long-windedness
Just trying to give back to the forum.

Scott.

__________________
2009, 3500, Auto, QuadCab, Short Box, 4x4, Sport Package, EGR unplug at 50km, Intake baffle removal at 250km, Espar D5 Heater, Tidy Tank Fuel+Tool 75 Gallon Aux. Tank

---

Last edited by Ahab : 09-07-2009 at 06:24 PM. Reason: add info

[-lenny-]

Man, this is great stuff. Lots of photos and detail. Definitely should be a sticky in the Tech section.

Mods? How about it?

__________________
08 MC 3500 68RFE
Mostly Stock

[TONKATOY2]

Another nice thing about this heater !! Even in -45C weather if you forget to progran it go out and start the heater for 30 mins and you are ready to go !!! She heats up really well!!!!

__________________
2008 6.7l Mega, Banks CAI, 5" TB exh,5050 Aero Turbine,EGR deletes. BD COOL-IT IC & Tran Pan,Oasis diff Ram Head, AIRDOG 150, SMARTY S67ME,Edge INSIGHT,Amsoil BMK-25, SRT 10 Hood, Bshwkr flares, ESPAR Htr, 3.5" IC PIPE Drv & pass side, WCC Intake Horn

[txpig]

Thanks for the great great write up!! I'd love to have that set-up on my truck, but I can't justify that kind of money while I live in Texas. I would be cool if they made one for A/C for the folks like me that live in a OVEN..

__________________
2008 3500, QC, SB, 4X4 Laramie, 68RFE, XRT, MP-8, 5" TBE, MPH trans tune, EGR/BlueTec Badge MIA, Volant Power-Core CAI, Raptor 150,Amsoil By-Pass, Mag-Hytec Trans & Rear Diff, Lorenz Bilstein 5100 System, PSC Steering Brace, B&W GN, Ride Rite bags

[jwaugh]

which fuel line is the return and how do you identify it?

[Ahab]

If I remember correctly, they are two different sizes and you could not attach the Y connector to the fuel supply line. The return line is the one disconnected in the picture.

If that is not true, then you could just go by the connector that is towards the front of the truck (at least on the trucks from the last couple years).

Or, you could trace it out to the CP3 I guess...

Scott.

__________________
2009, 3500, Auto, QuadCab, Short Box, 4x4, Sport Package, EGR unplug at 50km, Intake baffle removal at 250km, Espar D5 Heater, Tidy Tank Fuel+Tool 75 Gallon Aux. Tank

---

Last edited by Ahab : 09-28-2009 at 06:37 PM. Reason: add info