Diesel heaters provide reliable heat for vehicles, especially in cold climates, without the need to run the main engine. Their benefits include energy efficiency, reduced mechanical wear, and enhanced safety compared to other heating methods. However, proper installation is crucial to ensure optimal performance and compliance with safety standards.
This article offers a detailed, step-by-step installation guide based on information from technical documentation and manufacturer manuals. It covers preparation, mounting, electrical system setup, fuel and exhaust connections, and final checks. The goal is to provide a comprehensive reference for U.S. vehicle owners, DIY enthusiasts, and technicians installing diesel heaters in vehicles such as campers, boats, and commercial transport.
Preparation Before Installation
Before beginning the installation of a diesel heater, it is essential to prepare the necessary tools, materials, and installation environment to ensure a safe and efficient process. A well-planned setup minimizes risks and ensures the heater functions correctly.
Tools and Materials
Ensure that the heater package includes all required installation kits. Common tools needed for installation include:
- Screwdrivers
- Scissors
- Pliers
- Wrenches
- Electric drill
The installation process may require cutting or routing materials, so having the appropriate tools on hand is critical.
Choosing the Installation Location
Selecting the correct installation location is one of the most important steps. The location must:
- Be away from flammable materials and heat-sensitive components
- Allow for proper airflow and ventilation
- Avoid proximity to the engine or other heat sources to prevent fuel line exposure to high temperatures
For campervans, a common installation point is under the front seats on the side opposite the sliding door. This location helps reduce noise and improves safety by keeping the heater away from living areas. It is also recommended to install the heater inside a compartment or behind a bulkhead to further minimize noise and heat exposure.
Legal Compliance and System Check
Before installation, ensure all actions comply with local legal requirements. Keep relevant documentation, such as manuals or safety guidelines, accessible during the process.
Additionally, verify that the vehicle or boat’s system is suitable for the installation. This includes checking for any obstacles or factors that might interfere with the heater’s placement or function.
Mounting the Diesel Heater
After preparing the necessary tools and selecting an appropriate installation location, the next step is to mount the heater securely. This ensures stability and minimizes vibration and noise during operation.
Mounting Procedure
Install the Sealing Gasket: Begin by placing a sealing gasket on the diesel heater. This helps prevent leaks and ensures airtight connections.
Secure the Mounting Plate: Attach the mounting plate to the heater and apply a foam seal strip on top. This foam strip provides additional insulation and prevents heat transfer to surrounding structures.
Mounting Bolts and Support: Secure the heater and mounting plate to the chosen installation location using mounting bolts and locking nuts. If the installation surface is thin, additional support may be necessary to provide stable support for the heater system.
Electrical System Installation
Proper installation of the electrical system is essential for the heater’s safe and effective operation. Incorrect wiring can lead to performance issues or even fire hazards.
Connecting Power Cables
Carefully connect the power cables to the sockets on the heater’s casing. Ensure that the connections are firm to prevent poor contact.
Always follow the wiring diagram provided in the heater kit. This diagram illustrates how to correctly configure the wiring, ensuring all electrical connections are made according to the manufacturer's specifications.
Safety Tips for Electrical Installation
Disconnect Power Before Wiring: Always disconnect the power supply before starting any wiring work to prevent accidental electric shocks or short circuits.
Use Appropriate Tools: Use pliers, wire strippers, and other professional tools for wiring tasks to ensure safe and precise operations.
Professional Help: If you are unsure about how to correctly install the electrical system, it is advisable to contact a professional technician for installation or to provide guidance during the initial setup.
Cable Harness Rerouting
In some cases, the cable harness may need to be rerouted to the other side of the heater for easier installation. To do this:
Remove the Mainboard: Begin by removing the mainboard of the heater to facilitate cable rerouting.
Adjust the Cable Position: Relocate the mainboard cables of the heater to the other side.
Reinstall the Mainboard: After rerouting the cables, reinstall the controller and the cable harness back to their original positions, ensuring all connections are secure and stable.
Fuel and Exhaust System Installation
Correct installation of the fuel and exhaust systems ensures safe operation and minimizes environmental impact.
Installing the Fuel Line
Route the fuel line from the vehicle’s fuel tank to the heater. Ensure that the fuel line is not placed near the engine or other heat sources to prevent fuel vaporization or leaks.
Secure the fuel line with clamps or fasteners to prevent movement and potential damage.
Installing the Exhaust Pipe
Attach the exhaust pipe to the diesel heater. The exhaust pipe should be routed to an appropriate external location, ensuring it does not interfere with the vehicle’s structure or interior.
Use a gasket or sealant at the exhaust connection to prevent leaks and ensure airtight performance.
Final Installation and Safety Checks
Once the heater, fuel system, and electrical components are installed, the final steps involve securing loose components, protecting electrical connections, and performing a test run.
Securing Cables and Pipelines
Use nylon zip ties to secure all loose cables and pipelines. Ensure that all wiring is neatly arranged and won’t move or wear due to vehicle movement.
Avoid sharp bends or stress points in the fuel and exhaust lines to prevent leaks or blockages.
Protecting Electrical Connections
Apply a protective wax spray to all electrical connections. This helps prevent corrosion and minimizes electrical issues caused by moisture or dust.
Similarly, apply wax spray to the external components of the diesel heater to prevent rust and extend the lifespan of the equipment.
Final Inspection
After reassembling the vehicle panels and components, conduct a final inspection to ensure all devices function correctly without any missed steps or unsecured parts. This includes:
- Checking for loose bolts or connections
- Ensuring all components are properly mounted
- Verifying that the exhaust and fuel lines are secure and not obstructed
Test Run
Perform a system test run after completing the installation to ensure all functions operate as designed. Listen for any abnormal sounds or vibrations.
Check for leaks in the fuel and exhaust systems. If any issues are detected, address them before operating the heater regularly.
Maintenance and Long-Term Operation
To maintain optimal performance and extend the lifespan of the diesel heater, regular maintenance is essential.
Monthly Maintenance
- Start the heater for 15–30 minutes every month during the summer to keep the system active and prevent clogging or corrosion.
Component Replacement
- Replace the glow pin and glow pin filter every 2–3 years to ensure consistent and efficient operation.
Storage and Winter Use
- In cold climates, preheating the engine with the diesel heater reduces mechanical wear and extends engine life. This is particularly important for vehicles that are not used frequently during the winter months.
Conclusion
Diesel heaters are a reliable and efficient solution for heating vehicles, especially in cold environments. When installed correctly, they offer a safe and effective means of maintaining a warm and comfortable interior without the need to run the main engine.
The installation process involves several key steps, including preparation, mounting, electrical system setup, fuel and exhaust connections, and final checks. Each step must be approached with care and precision to ensure the heater operates safely and efficiently.
By following the manufacturer’s instructions and consulting professional assistance when necessary, users can ensure a successful and long-lasting installation. Regular maintenance further enhances the heater’s performance and extends its service life.