Well over the past few months ive noticed a damp patch under the van and the cooling fluid level falling. So last week i bit the bullet and decided to investigate. Turns out the Eberspacher cab heater was leaking from the water pump, mostt probably from the gasket between the heat exchanger and the burner unit and also the steel pipes supplying the water to and from the unit had rusted badly and were leaking.
So.... out came the heater and a Y piece of copper pipe was installed bypassing the heater and the rusting steel pipes. This kept the van on the road whilst I could work on the heater.
First I set about stripping down the Eberspacher. The one I have is a D5W on a W reg ex BT van. There's a datasheet here -
http://www.eberspacher.com/files/pdfs/water_pdf/D5W_manual.pdf
which might help anyone else one day. Its accurate except for the timer module - but as its good, I wasnt worried about that.
Note the pink stain on the clip that holds the heater together - been leaking there, so it will get the Hermetite instant gasket treatment.
View of wiring JB on top of heater - a bit of a tight squeeze here, and theres a dropper resistor here too (assuming it for the speed control of the air blower).
This is the insides of the heat exchanger - this butts up against the burner unit bit of the heater with no sign of a proper gasket. As for the inner and outer bits of the h. exchanger - they couldnt come apart but Im sure they are leaking from here. Loads of instant gasket sealer will have to be applied.
The burner unit that insterts into the heat exchanger. Sothing wrong with this, so all it got was a cleanup on the face that goes against the heat exchanger.
Two parts of heater joined back up- gasket sealer in place. Ive since had to upen this joint up and add loads more gasket sealer to stop a leak. Just hope its worked)
The water pump was dripping loads as well, so that also got the instant gasket treatment. That held well and hasnt leaked since touch wood.....
As for the steel pipes - they had rusted to f*** and had to go. Having spoken to Kreuger - my locak Eberspacher dealer) they scared me off with silly prices, so the pripes were gonna be made in copper.
Only Ford would use steel pipes for this eh....
Dad and I made up these - came out quite well using the pipe bender.
New pipes in place, connected to the calorifier engine and heater matrix.
Heater back under van, being put through its paces.
And so far it works - although there was a slight weeping from the heat exchanger, some more instant gasket seems to have fixed it for now - time will tell.
And on a side note I have also been busy on security and gadgetry......
Fitted this big bugger. - Rusts quickly though, but cant complain as it was given to me by Dad.
Me and my BF made a little sheet of perspex to hold the sat nav sucky cup thing onto. The perspex then clips onto the map holder thingie on the dash of a MK5 - no marks on the windscreen then
Then I invested in a reversing camera - made a little box for it out of 50x50 galv trunking.
This connects up to a new monitor which is rather tasty...
Alpine head unit (plays dvds onto the screen), freeview box hidden away to watch tv, and the camera on the back. The 6.5 inch screen disconnects easily to take out the van when its parked up too. Looks like a rear view mirror up there and its the dogs b**locks..
So yeah, Ive been a bit busy tinkering away on my baby