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Old 10-22-2018, 04:10 AM   #1
My Sprinter's A Lemon
 
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Default Heater muffler missing a hose

My "lemon" came to me missing some parts.

It appears there is a hose missing. Can I buy this hose or do I need to buy the muffler with it?

Incidentally, I understand this muffler actually muffles the noise but there is no noise. Can someone offer some insight as to why and what I may be looking at in terms of repairs to this system?

Thanks
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Old 10-22-2018, 04:50 AM   #2
Nautamaran
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Default Re: Heater muffler missing a hose

The espar heaters can certainly be finicky...
I’d say the most common failure mode is for the fan to jam, so your first step is to ensure the fan is able to spin.
Then then check that the control board isn’t fried;
then the dose pump, ignition coil, and flame sensor.

This post describes my experience last month... though your unit’s screws may not cooperate as well as mine did, so be prepared to bring the unit to a bench to work on it with heat and penetrating oil.
(there are photos of the turbine fan in the original post if you click on the blue triangle)

-dave

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Originally Posted by Nautamaran View Post
So... I removed the grille and headlamp and loosened the two mounting screws holding the Espar into its bracket. With the exhaust and intake hoses disconnected I then had enough slack in the rubber coolant hoses to gain good access to the Espar’s housing bolts, so I decided to attempt to lube the fan with the unit in place. All my fasteners were prestine, so this too went smoothly, but if any had been stubborn this story would have ended right there...

With the fuel line removed and the fan cap’s four screws out, the cap came off easily and I confirmed that the turbine dome was spinning freely. However I found it was scraping a bit on the top plate. On further inspection I found there was a small amount of mineralized crust under the rim of the turbine dome and the lip of the cap plate. Not much, but enough to throw things off balance. So I used a small scraper to de-scale the metal surface and the plastic lip under the cap, and rinsed the surfaces well with silicone lubricant spray.

I also removed the four screw holding the end cap to gain access to the fan motor. Its lower bearing was very clean, but I gave it a soaking of spray lube.

I believe that this is as far as you can disassemble things without opening the water jacket and leaking coolant, so I didn’t disturb the horizontal screws behind the fan motor that hold the flame tube into the jacket casing.

Reassembly of the end and top caps was straightforward, with a dab of nickel antiseize on the threads of the eight machine screws and on the aluminum mating surfaces.

The unit now runs “quietly” again, and I have concluded that the howl was undoubtedly caused by the fan/motor assembly not running true.

Thanks to all,

-dave
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Old 10-22-2018, 05:06 AM   #3
Nautamaran
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Default Re: Heater muffler missing a hose

This is the missing 24mm exhaust hose:

https://www.amazon.com/Eberspacher-W.../dp/B00VV5BVVK

A local dealer may carry it for less?

-dave
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Old 10-22-2018, 05:33 AM   #4
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Default Re: Heater muffler missing a hose

I am not capable of diagnosing this myself. I guess I'll have the dealer check it out.

Thanks for your help.
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Old 10-22-2018, 12:01 PM   #5
Patrick of M
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Default Re: Heater muffler missing a hose

Quote:
Originally Posted by My Sprinter's A Lemon View Post
I am not capable of diagnosing this myself. I guess I'll have the dealer check it out.

Thanks for your help.
Do you have the 7 day timer on your dash? If so you can diagnose without a dealer.

Oh and my muffler flex pipe had rusted away as well, i think I made a hard line out of 3/4” copper pipe or something, works fine. Just makes removing the unit harder , the original,is a thin walled metal corrugated tube, so whatever works. The Espar parts are unreasonably expensive .
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Last edited by Patrick of M; 10-22-2018 at 12:07 PM.
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Old 10-22-2018, 02:32 PM   #6
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Default Re: Heater muffler missing a hose

No, no timer.
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Old 10-22-2018, 03:24 PM   #7
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Default Re: Heater muffler missing a hose

Your average dealer will have zero knowledge of the espar, much less the inclination to fix it.
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Old 10-22-2018, 03:38 PM   #8
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Default Re: Heater muffler missing a hose

You can diagnose this yourself. You can start with the fan being seixpzed or not if you can get the cover off in situ, then the FP, touching the lead to the FP on and off should produce squirts of fuel, after that its time to remove the unit for some bench testing. Bunch of threads here on the Espar, it is a great simple unit, but the van interface is a little complex.
Fwiw it’s real value is as a pre heater for cold winter starts, there is a thread detailing how to get yours to run before the engine runs, (without the timer your Espar is only supposed to work while the engine is runnning).
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Old 10-22-2018, 03:55 PM   #9
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Default Re: Heater muffler missing a hose

Without the espar running, do you suspect the warm air from just the engine will heat up an enclosed cab area during cold winter days ....or am I dreaming that I won't freeze without the espar running?
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Old 10-22-2018, 04:01 PM   #10
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Default Re: Heater muffler missing a hose

I second Patrick’s opinion. If you own the right torx driver the unit is NOT complex and I encourage you to give it a go.

- Four screws on top expose the fan dome
- four screws on the end expose the fan motor and remove the control module
- two rubber hoses on top carry engine coolant
- two metal tubes out the bottom supply air and exhaust
- an external fuel “dose pump” clicks and spurts fuel, once per power cycle

Deeper within the housing there is
- an igniter (glow plug) to light the fire
- a flame sensor (pyrometer) to confirm ignition
- water temp sensor to prevent overheating

Often the fan jams up on dirt or grit and it stops spinning, so it’s well worth your time to pull the headlamp off and try to turn the four top screws out, then turn the dome by hand.

A sprinter-specific manual is here, with a parts list and exploded drawing at the end.
http://diysprinter.co.uk/reference/e...ter_manual.pdf

Good luck,

-dave
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