Sylvie Willis
Diesel heaters are a great way to keep your van warm during winter. However, the installation process can be challenging, especially when it comes to finding the right spot for the fuel tank. The fuel tank's placement is crucial to ensure the heater's functionality and safety. While some prefer to connect the diesel heater to the vehicle's main fuel tank, others opt for a separate, dedicated fuel tank for the heater. The shape and size of the fuel tank play a vital role in determining its location, as it needs to be accessible for refuelling while also being securely fixed to prevent damage during travel. Additionally, considerations such as fuel type, tank material, and ventilation are essential to ensure the safety and longevity of the fuel tank and the diesel heater system as a whole.
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What You'll Learn
Fuel tank placement considerations
Fuel tank placement is a crucial aspect of ensuring optimal performance and safety in diesel heaters. Here are some considerations to keep in mind when deciding on the placement of your fuel tank:
Accessibility and Convenience:
The fuel tank should be placed in a location that is easily accessible for refuelling. Consider placing it near doors or openings to facilitate the refuelling process and reduce the risk of spills. Ensure that the tank is not placed too far from the fuel pump to avoid complications with fuel lines.
Safety and Spill Prevention:
Flammables inside a vehicle can be hazardous, so it's essential to take precautions to prevent spills and damage. Securely mount the fuel tank in an upright position and ensure it is properly fixed to avoid damage from moving cargo. Consider the tank's proximity to sidewalls in case of collisions, and always be cautious to avoid spills during refuelling.
Tank Shape and Space Constraints:
The shape of the fuel tank can significantly impact its placement. The standard fuel tanks that come with diesel heaters tend to be tall and flat, making them challenging to fit inside existing structures like bench seats. Consider using a more appropriately shaped tank or consult instructions for customising the fuel tank setup to fit your specific space constraints.
Protection from Ultraviolet Rays:
Ultraviolet rays can penetrate white plastic fuel tanks, causing deterioration of the diesel fuel over time. If you're using a clear white oil tank, ensure it is installed away from direct sunlight. Consider using a black plastic tank, a stainless steel tank, or adding a cover to the tank to minimise UV damage.
Distance from Heater and Fuel Line Dynamics:
The distance between the heater and the fuel tank is critical for optimal performance. A comprehensive understanding of fuel line dynamics is necessary to determine the maximum distance. Factors such as fuel line diameter, fuel viscosity, line length, and pump capacity all play a role in ensuring proper fuel flow and heater efficiency. Refer to manufacturer guidelines and recommendations for specific heater models to make an informed decision about fuel tank placement.
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Connecting the diesel heater to the vehicle's main fuel tank
There are a few different methods to connect the diesel heater to the vehicle's main fuel tank. One method is to drill a hole in the top of the tank and install a standpipe. This method can be done with a hand drill, and it is recommended to leave a distance of more than 2 cm (3/4 inch) between the fuel tank and the standpipe to allow any contaminants in the diesel fuel to settle at the bottom of the tank. Another method is to tap into the vehicle's fuel line or use one of the extra ports on the fuel sending unit. It is important to note that drilling into the fuel tank can be a tricky process, and it is recommended to have as little fuel as possible in the tank when doing so. Additionally, it is important to seal the new outlet properly to prevent any fuel leaks.
When connecting the diesel heater to the vehicle's main fuel tank, it is important to consider the location of the fuel filter, fuel pump, and main engine. The fuel filter should be installed at the fuel pump's inlet to effectively filter the fuel and prevent contaminants from clogging the pump. The direction of fuel flow should also be considered, as the filter outlet should be connected to the inlet of the fuel pump. The fuel pipe lengths should be kept to a minimum, with a maximum of 2 meters between the fuel tank and the fuel pump and a maximum of 5 meters between the pump and the heater.
It is also important to choose the right type of fuel tank for the diesel heater. Many manufacturers choose a white plastic fuel tank, but this type of tank is not ideal as ultraviolet rays can easily penetrate and reach the diesel fuel inside. This can lead to fuel deterioration, which can clog the heater's fuel delivery system, filter, and pump. Instead, it is recommended to choose a black plastic fuel tank or opt for a stainless steel tank, as these materials will protect the fuel inside the tank. Additionally, consider choosing a tank with a lock to prevent theft and tampering.
Overall, connecting the diesel heater to the vehicle's main fuel tank can be a feasible option, but it is important to carefully consider the different methods, the location of the fuel filter and pump, and the type of fuel tank to ensure a proper and safe installation.
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Mounting the fuel tank inside the vehicle
One option is to mount the tank under the hood, in the top right empty space near the hinge. This option is popular, and the engine compartment heat will prevent the fuel from gelling. However, you should be aware of potential rub points on the plastic tank.
Another option is to bolt the tank under the front seats, making it easy to fill up at petrol stations. You can also mount the tank inside the vehicle by creating a custom-built aluminium tank that fits between the frame rails on the passenger side. An access panel under the mat with a double-sealed door allows for refuelling. To prevent a fuel smell, add pieces of fuel cell foam to the tank.
If you are concerned about the flammability of diesel, mounting the tank inside the vehicle may be safer than mounting it outside. However, it is important to consider the potential risks of spills or damage to the tank by moving cargo.
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Mounting the fuel tank outside the vehicle
Mounting a diesel heater fuel tank outside your vehicle is a viable option, and there are several ways to go about it.
One method is to use the panelling below the gas tank hatch for the diesel fill port. This approach ensures that refuelling is convenient, as you can fill up both your gas and diesel tanks at the same time. However, keep in mind that this setup might result in dual fuel, which some may find cumbersome.
Another option is to install an undercarriage auxiliary tank. This method involves repurposing the DEF port for filling the heater fuel tank. To monitor the fuel level, you can install a fuel level sensor connected to a gauge inside your vehicle. However, keep in mind that diesel heaters tend to clog above 6000 feet, so be sure to read reviews before installing this type of heater if you plan to camp or drive at high elevations.
If you're looking for a more affordable option, you can opt for a cheap Chinese diesel heater and install a poly tank right below and behind the gas filler. You'll need to swap out the fuel door for the diesel version, and ensure proper ventilation to avoid unpleasant odours when driving in mountainous areas.
When mounting the fuel tank outside, it's important to consider the climate you'll be operating in. Regular diesel can gel near freezing temperatures, so if you're in an area that gets very cold, consider using a winter blend that contains additives to prevent gelling.
Additionally, you can mount the tank outside the vehicle and cut a hole in the side to route the spout of the gas tank externally. This allows for external refuelling while keeping the tank secure inside.
Finally, when mounting the tank outside, ensure that it is securely fastened and doesn't obstruct any moving parts or hot components. Use zip ties to secure the fuel lines and consider sleeving the nylon line with a larger diameter tube for added protection.
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Considerations for the shape and material of the fuel tank
The shape and material of the fuel tank are important considerations when installing a diesel heater. The fuel tank's shape should allow it to fit in the desired location without interfering with other components. Tall and flat tanks, for example, may be challenging to fit inside existing structures like bench seats. However, their flat shape allows for easy mounting by screwing them in place, provided the tank's lid is accessible.
The material of the fuel tank is crucial for safety, durability, and performance. Plastic tanks, for instance, are susceptible to UV damage, with white plastic tanks being particularly vulnerable. Prolonged exposure to UV rays can cause fuel deterioration, leading to clogs in the heater's fuel delivery system. Black plastic tanks offer some protection against UV rays, but stainless steel tanks provide superior resistance. Aluminum tanks, especially those made from 5052 alloys, offer high corrosion resistance to harsh solvents like gasoline and saltwater, making them suitable for fuel storage. Polyethylene tanks are also a popular choice due to their lightweight nature, easy installation, and superior stress-cracking resistance.
In addition to the material's resistance to corrosion, temperature fluctuations can also impact the fuel tank's durability. Elevated temperatures can accelerate chemical reactions, causing corrosion in metals like steel, while cold weather can lead to material contraction and hardening, potentially resulting in damage. Therefore, it is essential to consider the environmental factors the fuel tank will be subjected to when selecting the appropriate material.
Compatibility with specific fuels is another critical factor in choosing the right fuel tank material. Different fuels require specific tank types to prevent corrosion and maintain efficiency. For example, polyethylene tanks are effective for storing corrosive chemicals due to their corrosion resistance and durability. Assessing the corrosive impact of the fuel on potential construction materials is an important consideration to ensure the longevity of the tank and prevent leaks.
Finally, consider the location of the fuel tank and any relevant local regulations or safety standards. For instance, mounting the tank inside a vehicle comes with the risk of flammables and the challenge of refuelling, positioning, and securing the tank to prevent damage from moving cargo. Grounding the tank to the vehicle's chassis is recommended. Additionally, ensuring that the tank is not too far from the fuel pump is crucial, with a maximum recommended distance of 2 meters between the tank and the fuel pump.
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Frequently asked questions
There are several options for fitting a diesel heater fuel tank in a van. Some common places include:
- Under the seats
- Behind the driver or passenger seat
- Under the bed or in a cupboard
- In the front boot or tunnel boot
- Under the floor
- Inside the back door
When choosing a location for the fuel tank, it is important to consider the accessibility for refueling, the proximity to the fuel pump, and the safety of the location. It is also important to use a suitable tank that is not made of white plastic, as ultraviolet rays can penetrate white plastic and cause fuel deterioration.
To install the fuel line to the tank, you can use either the fuel nozzle or the fuel standpipe. If using the fuel nozzle, drill a hole on the side or bottom of the tank and use a wire to feed the nozzle through the tank. Once the nozzle is attached, add a washer, a nut, and the fuel line. If using a white nylon fuel line, you will need a piece of rubber joint. If using the fuel standpipe, install it on the top of the tank on an even surface.
The fuel pump should be mounted near the diesel heater, preferably within 2 meters of the fuel tank. The fuel pump should be installed at an incline, with the discharge end rising up at an angle of 15* to 35* above the inlet. The fuel lines and components must be placed away from any heat sources, such as vehicle exhaust piping or the engine compartment.
One common issue with diesel heater fuel tanks is the accumulation of substances at the bottom of the tank, which can clog the fuel pump. To prevent this, it is recommended to install the fuel tank standpipe with some spare room at the bottom of the tank, leaving at least 2 cm between the bottom of the fuel tank and the standpipe. Another issue is the smell of fuel inside the van, which can be addressed by using pieces of fuel cell foam in the tank.
