Disco 2 Fuel burning aux heater install

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rewmer

Well-Known Member
Posts
2,082
Location
Clacton, Essex, UK
Starting to collect some bits for this project but have come a little unstuck finding details of the bracket to mount the webasto heater onto the bulkhead. Microcat isn't giving any clues or part numbers...
If anyone has such a thing fitted, any chance of a picture or two so I can at least make my own.
This is going to be "How too" when I've collected all the parts required so any help will be logged and published. If I go down the route of making my own, I will get several laser cut to help out any other who may be inspired by my efforts.......
 
Well Ive got the heater up and running on the bench in the shed, all that is stopping me now is the mounting brackets. Ive seen a few aftermarket ones, but really want to keep this OE. Ive tracked down the bracket that bolts to the heater, but now I need details of the part/s that mount to the bulkhead.....
 
How have you gone about this so far then? I'd be interested to know what you've assembled it all from, as I know these are cheap on eBay, but the heaters usually come bare as a part to swap in/out of a car with them already installed. I do have a chap who can supply a loom though..
 
I acquired a Thermo top C/Z from a BMW3 series E46 (first mistake ) along with a dosing pump a length of fuel line and some exhaust pipe from a guy on eBay - £140 the lot.
Spent a while trying to get it to bench run before I discovered that the BMW units (and Mercedes) have different controller boards that require a can bus signal to start.
Anyway, bought a replacement board from a guy in Lithuania - about £90 delivered, and then diagnosed a duff glow plug as it kept faulting on the ignition stage (second mistake ).
Another £50 for a glow plug and it was still the same - Turned out my test battery was duff coupled with too small wiring for the main supply was causing enough voltage drop for it to fault when the glow plug called for power.
Managed to source a genuine fuel line from pump to heater - eBay again £12 !!!.
Bench test is now all good, fires up good with no smoke and a good clean burn.

Did have some good luck, in the engine bay where the OE heater sits, I found the two plugs for the heater. Tested the power feed and it was live !! - no fuses or relays to fit, and then whilst
changing the exhaust found the plug for the pump just in front of the tank so no real wiring to do except apply a +12v signal to pin one on the heater to start, this I intend to do with a remote relay = eBay again £6 from china - works a treat.

Make note - the supply hose to the heater has to be 2mm bore- otherwise the dosing to the heater is thrown out. Bench testing I used a standard bit of fuel line from tank (lemonade bottle ) to pump and this seemed to work ok.
The other thing to consider is a pick up tube in the main fuel tank. I've got a length of 6mm OD copper pipe and a bulkhead fitting I'm going to use to achieve this.

The word on the street is a Rover 75 unit is OK to use, find a breaker with a complete car to get the heater , pump and exhaust.
If my wiring to the pump checks out ok, I have a spare pump lead that I'm happy to donate to someone's cause if required.
 
Wonder if the FPR from a hatchback Saab 93 would work?
I had a few diesel 93,s all of them were fitted with FPR,s as standard, must be quite a few lurking about in reclaimation yards now.
Mark
 
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