Sylvie Willis
BD diesel fuel heaters are designed to prevent cold weather fuel gelling in vehicles. When temperatures drop, diesel can become very viscous, causing hard or no-start situations. The most efficient solution is to heat the fuel at the fuel filter, which is exactly what the BD diesel fuel heater does. This heater is simple to install and works in conjunction with an AirDog Fuel System. Before installing your diesel heater, it is important to ensure you have all the necessary tools and materials, as well as choosing the right installation location to ensure optimal operation and safety.
Characteristics and Values of Installing a BD Diesel Fuel Heater
| Characteristics | Values |
|---|---|
| Installation Location | Dry and safe, flat surface, accommodates exhaust pipe length, no flammable materials or fuel lines nearby, exhaust outlet points downwards, horizontal or tilted 15°-30° |
| Tools and Materials | Screwdriver, scissors, pliers, wrench, electric drill, mounting bolts, locking nuts |
| Fuel Tank | 10L plastic fuel tank included in the kit, option to install a larger 20L tank, ensure tank has a fuel-union fitted |
| Fuel Supply Pipe | Small-diameter, hard-nylon pipe, protect with hose pipe, connect to the bottom of the fuel tank |
| Fuel Fill Port | Connect one end to the barb fitting on the fill port, other end to the top of the fuel tank, ensure vent hose is not pinched |
| Exhaust Pipe | Attach to the heater, ensure it is not too long, direct exhaust outlet downwards |
| Power and Voltage | Choose a heater with appropriate power and voltage for your vehicle type and heating requirements |
| Maintenance | Start the heater for 15-30 minutes every month during the summer to ensure optimal performance |
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What You'll Learn
Installation location
Choosing the installation location for your diesel heater is a critical step in the installation process. It ensures optimal operation and safety. Here are some key factors to consider when selecting the installation location:
Dry and Safe
It is important to choose a dry and safe location for your diesel heater. Avoid areas where moisture or potential damage might occur. Ensure that the chosen location is free from any flammable materials or fuel lines, as this is crucial for safety.
Flat Surface
Opt for a flat surface to mount the heater. This helps to maintain its stability and efficiency. Avoid mounting the heater in locations that could propagate vibrations or noise, such as cabin bulkheads.
Exhaust Pipe Considerations
Consider the length and position of the exhaust pipe when selecting the installation location. Ensure that the exhaust outlet points downwards to avoid any hazards, and that there are no flammable materials or fuel lines near the exhaust pipe during operation.
Installation Angle
The heater should be installed horizontally or at a tilt angle of 15° to 30° to ensure optimal performance. The fuel pump should also be installed at an incline, with the discharge end rising up at an angle of 15° to 35° above the inlet.
Air Intake
Position the air intake in an area with sufficient clearance to allow for the proper flow of air. Ensure that the air intake is located away from any obstructions, sources of debris or dust, and that there is ample clearance for ducting, wiring, and fuel tubing.
Fuel Tank and Pump
Familiarize yourself with the location of the vehicle's fuel tank and consider the routing of fuel lines. The fuel pump should be mounted near the diesel heater but no more than 2 meters away from the fuel tank. Ensure that the fuel lines are not near any heat sources, such as the engine or vehicle exhaust piping.
Control Panel Height
If your diesel heater has a control panel, it is recommended to install it halfway up the height of the cabin. This will ensure optimal heater operation and fuel efficiency.
When selecting the installation location, always prioritize safety and adhere to local legal requirements.
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Required tools and materials
Before installing a diesel heater, it is important to ensure you have all the necessary tools and materials. The specific items required may vary depending on the heater model and the vehicle or space where it will be installed, but here is a comprehensive list of tools and materials that are generally needed for the installation process:
- A screwdriver
- Scissors
- Pliers
- A wrench
- An electric drill for drilling holes
- Mounting bolts and locking nuts
- A fuel tank (some heater kits come with a plastic fuel tank, but you may prefer to purchase a larger metal one separately)
- Fuel supply pipes or hoses (nylon or hard nylon)
- A fuel pump
- A fuel filter
- A fuel gauge (optional)
- A heater controller (optional)
- A dip tube (optional)
- A fuel union and nut (if you drill a hole in your fuel tank)
- An on/off valve (optional)
- Hose pipe (to protect the fuel supply pipe)
Additionally, when choosing the installation location, consider the following:
- Opt for a dry and safe location, avoiding areas where moisture or potential damage might occur.
- Choose a flat surface to mount the heater for stability and efficiency.
- Consider the length and position of the exhaust pipe. Ensure it is routed away from flammable materials and fuel lines.
- The exhaust outlet should point downwards to avoid any hazards.
- The heater should be installed horizontally or at a tilt angle of 15° to 30° for optimal performance.
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Fuel supply
Selecting the Fuel Tank
Firstly, choose a suitable fuel tank that meets your heating requirements. The heater kit typically comes with a 10-litre plastic fuel tank. However, if you want to avoid frequent refuelling, consider installing a larger fuel tank, such as a 20-litre tank, that can be securely placed under the vehicle or in an adjacent shed. Ensure the tank has a vent hole in the fuel cap to prevent any issues when filling the tank.
Mounting the Fuel Tank
When mounting the fuel tank, consider stability and safety. For instance, if you opt for a 10-litre tank, you can mount it on a flat surface inside a wooden shed, adjacent to the heater. For larger tanks, you may need to utilise the cavity under the vehicle, ensuring it is securely held with appropriate tubing and fastened with nuts and bolts.
Connecting the Fuel Supply Pipe
The fuel supply pipe delivers fuel from the tank to the heater. It is crucial to protect this pipe from damage. One effective method is to thread the pipe through a hose pipe, guiding it safely from the tank to the heater. Ensure the pipe is not pinched, as this can cause air bubbles and spills during refuelling. The fuel supply pipe should connect to the bottom of the fuel tank and the intake side of the fuel pump.
Priming the System
To prime the system, open the tap and temporarily disconnect the fuel supply pipe from the filter. As diesel starts flowing out, reconnect the pipe to the filter. This process ensures that any air is removed from the lines, and the system is ready for operation.
Additional Considerations
When working with fuel supply, it is essential to adhere to safety precautions. Ensure that the fuel lines are not near the engine or other heat sources to mitigate potential fire hazards. Also, keep flammable materials away from the heater and its surroundings. Finally, always refer to local legal requirements and regulations when installing and operating your diesel heater.
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Exhaust pipe
The exhaust pipe is an essential component of a diesel heater installation. Here are some detailed instructions and considerations for installing the exhaust pipe:
When choosing the exhaust pipe for your diesel heater, noise should be a key consideration. To minimise noise, opt for a flexible spiral exhaust pipe. This type of pipe provides superior sound deadening compared to rigid pipes. A flexible pipe is also easier to bend and shape to your desired configuration.
Installation Location:
The location of the diesel heater should accommodate the length of the exhaust pipe. Ensure that the exhaust outlet points downwards to prevent any safety hazards associated with the hot exhaust gases. The heater should be installed horizontally or at a tilt angle of 15° to 30° for optimal performance.
Maintain a safe distance between the exhaust pipe and critical vehicle components, especially flammable parts such as wiring, fuel pipes, and brake hoses. Avoid mounting the heater near cabin bulkheads or other areas that could propagate vibrations and noise.
Installation Process:
Attach the exhaust pipe to the diesel heater along with the fuel and intake pipes. Secure the heater and mounting plate to the chosen installation location using mounting bolts and locking nuts. Ensure that the exhaust pipe is securely fastened with heavy-duty clamps at intervals of about 50 cm to prevent damage due to vibrations.
When cutting the exhaust pipe to size, use a sharp cutting tool to make precise, smooth cuts, avoiding any crushing of the interfaces. If the supplied hose clips are too small or too big, consider upgrading to better-quality ones to ensure a tight seal and prevent carbon monoxide poisoning.
Safety Considerations:
The exhaust system of a diesel heater can heat up quickly, so always follow safety guidelines during installation and operation to avoid burns or other incidents. Ensure that there are no flammable materials or fuel lines near the exhaust pipe, and that the exhaust outlet is positioned outside the vehicle to prevent exhaust gas accumulation.
Keep in mind that the exhaust pipe can eject water vapour, so it is important to avoid creating a water trap in the pipe routing. Additionally, the exhaust muffler may have a small hole to allow condensation droplets to escape, so ensure this hole is facing downwards during installation.
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Safety and legal compliance
Safety should be a primary concern when installing a BD diesel fuel heater. Before you begin, ensure you have all the necessary tools and materials, including any required installation kits. Planning the installation location is critical to safety. Familiarize yourself with the location of the vehicle's fuel tank and battery, and choose a dry, safe, flat surface to mount the heater. Avoid any areas where moisture or potential damage might occur, and ensure that the exhaust pipe length is accommodated. The exhaust pipe can become very hot during operation, so it is crucial that there are no flammable materials or fuel lines nearby. The exhaust outlet should point downwards to avoid hazards. The heater should be installed horizontally or at a tilt angle of 15° to 30° to ensure optimal performance.
Special attention must be given to the routing of fuel lines. Ensure that the fuel lines are not near the engine or other heat sources. When heaters are used in confined spaces, such as caravan and truck cabins, adequate ventilation is essential to prevent carbon monoxide poisoning. A carbon monoxide detector can also be installed for added safety. During installation, avoid tying up extra cable randomly, as this can cause electromagnetic interference and lead to inadequate fuel supply. After installation, the fuel line should be unplugged from the pump to the heater, and then reconnected after starting the heater to allow fuel to fill the line without air inside.
From a legal compliance perspective, ensure that all installation actions comply with local legal requirements and keep all relevant documents on hand. Check that the vehicle's system is suitable for installation and there are no obstacles or factors that might affect the process.
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Frequently asked questions
The BD diesel fuel heater kit is used to prevent cold weather fuel gelling. Diesel has the ability to become very viscous when temperatures drop, which is referred to as "gelling". This can lead to hard or no-start situations.
The kit includes a self-regulating 320-watt heater that is sandwiched between the filter head and water separator of a compatible fuel system. The heater is simple to install and has a pre-made wiring harness with sealed electrical connectors.
It is important to choose the right installation location, ensuring it is dry, safe, and on a flat surface. The exhaust pipe should be accommodated for length and positioned away from flammable materials or fuel lines. The exhaust outlet should point downwards, and the heater should be installed horizontally or at a tilt angle of 15° to 30°.
