Installing an Espar

[Shadrach]

I had an Espar on my 03 and the 08 I bought this summer doesn't have one. I bought it from a friend who was the original owner. I suggested to him when he bought it new that he should install one but he never did. I sure wish he had because then I wouldn't have to do it. Unlike him I park outside so I wanted one.

Some background: For those of you who don't know an Espar ( their real name is Eberspaecher - it's German ) is a diesel fired engine heater, kind of like a block heater but uses fuel to create the heat. It heats the coolant and pumps it thru the engine. There are other brands, like Wabasto and Proheat, and the heaters can heat coolant or air. Since I sell Espars that's what I use. The model I used is a D5 and it puts out 5 kilowatts of heat, or 17,100 BTU's, about 6.5 times as powerful as the factory block heater. They make a proper Dodge kit which fit 2003-2012 years, P/N 252822190532. The kit includes a wiring harness which splices into the cab heater motor and will turn on the cab fan. This only works with the 2003-2009 trucks. The kit will work on a 2010-2012 truck as well but because of wiring differences you can't use this feature.

So back to my installation on the 08. The kit is expensive, but if you want something you can usually justify it and since I live in a climate where it does get cold and I can get a "deal" on one I wanted to install one on this truck as well. Instead of buying the proper kit this time I used a universal model. I never used the in cab heat feature on the 03 anyway. I got a super good deal on it because I scrounged up enough pieces to make up my own "kit". I bought the proper mounting bracket for the Dodge and the fittings to connect to the fuel tank so I wouldn't have to drop the tank to install a pickup tube. On the inside of the Left frame rail just in front of the fuel tank there is a bracket sticking out at the top of the frame rail with 2 tabs with thread holes and below that 2 threaded holes in the frame. The Dodge Espar bracket mounts to this.

#ad


The fuel connections are easy. On the 03 it was just pull the rubber cap off the extra nipple on the sender and attach the Espar fuel line. On the 08 I had to remove the return line and insert a "Y" put the line back on and attach the Espar line to the other side of the "Y". The heater that come with the Dodge kit has internal fuel and water pumps, my heater had remote mount ones.

The 08 version. I blew off the sender with an air hose and stuck my cell phone up there to take the picture as I couldn't get my fat head up high enough.

#ad


#ad


The 03 version. I had the box off so it was easy to do it then.

#ad


I mounted the fuel pump on the frame with it angled up at the front and put the water pump on the transfer case skid plate.

#ad


I used Goodyear Hi Miler HD heater hose and ran the along the frame rail and up to the Righthand side of the engine. I put shut off valves in the hoses so I could remove the heater for servicing later.

#ad


I wrapped them in old hose to keep them from rubbing on the fuel lines and wiring.

#ad

 

[Shadrach]

Here are some more pictures:

These are of the heater from the Dodge kit mounted in the Dodge bracket. You can see how the bracket is designed to mount to the frame. The heater has the fuel and water pumps inside the unit.

#ad


My flat top heater in the Dodge bracket. You can see here the water pump in the bottom right hand corner. I added the optional muffler to take the "whoosh" out of the noise. It echoed off my garage walls and the fence.

#ad


I ran all the wiring up and thru the firewall. This way all my connections are inside and away from the weather.

Hooking it up to the engine was easy, altho it is a bit awkward because the cowl covers the back half of the engine. There is a pipe sticking up from the head just above the exhaust manifold and one of the heater hoses attaches to this. I removed the hose and attached my new hose to it and with a coupler put the other one on the the heater hose I had removed, thus making the hot coolant go thru the heater and the engine.

I have a 24 hour timer in the cab and I can either choose one of 3 presets of my choice to program the heater to come on at say 5 AM or I can just push the on button . I runs for a max of 2 hours and uses vey little fuel and battery power..

People tell me all the time that a remote start is cheaper and while it is you are still starting a cold engine. I use my heater all year round to keep it in good operating condition. In the summer when I and camping in the mountains it can get quite cool. Turning it on for half an hour while I and getting ready to hitch up means I am not going to be hitting the hills with a cold engine.

 

[DonFitzwater]

I really like the Espar for supplemental heat.....-50 and the engine alone makes very little heat for the cab. Turn on the Espar and you've got all the heat you want.

 

[Ozymandias]

Nice write up, I have an Eberspächer too - there is only one thing that is sad with the Espar Mounting Kit - they go the easiest way and mount the Heater down there in dirt an wet.

I installed my Heater right unter the Airfilter Box, vertically, a nice place, dry and mostly clean behind the plastic wheel well. And so the waterhoses lengthen only around 5 feet.

 

[Mikey-KE7LBB]

Best purchase I've made to date!

It is nice to crawl into a warm truck with (mostly) defrosted windows when it's below zero outside . Another plus is the fact that it used less amperage to do all of that than when you just start a truck that has been sitting in the cold.

I haven't seen my grid heater light come on at all when I have the timer set just right. The only cold starts I've had over the last 3 years have been when the fuel level was too low or I got off work before the set time.

 

[Shadrach]

When we started installing them on Dodges years ago we mounted them in the engine compartment, but on a modern truck there is little extra space. I don't drive mine in the mud or in deep snow so for me it isn't a problem having it underneath the truck. I don't drive the truck daily in the winter as I work only 5kms ( about 3 miles ) away so even with the preheat and the Mopar winter front it wouldn't get up to operating temp.
David

 

[Shadrach]

Here is a picture of the 24 hour timer that I have in my Dodge

#ad


This is how I attached the hoses. The black on is from Dodge and the blue ones are the ones I added for the heater.

#ad

 

[User113]

Shadrach,

I've been looking for one of those "Dodge" models, where do they sell them?

 

[Shadrach]

try here:

39575 Lewis Dr., Bldg 2, Suite 900
Novi, Michigan 48377

Phone: 800-387-4800

 

[buzzinghalfdozen24]

This thread is genious. I added an M12 kit to my truck. I love it. I didn't have any luck two winters ago getting proper instructions and never knew there was actually a kit made for these trucks. I did mine quite a bit different. I think its about twice as big. I mounted mine in the truck bed, on a small took box. A few quick connects, and its removable to the next vehicle.

I need to find one of those timers though. I gave up on the timer as I had to customize every piece of mine.

Winter functions while its blowing and snowing, and 0 deg, I just leave it run for 2-3 hrs. It doesn't drain the batteries much till I kick on the cab blower fan. I hate fluctuating engine temps.