Eberspacher D4S Heater problem

[Pierrot]

Hallo!

First if all sorry not writing in German, I am french and living in Bretagne. I am the proud owner or a 2005 316cdi JC bought in the Netherlands but originating from Germany.
I have some trouble with the heater. When launching it from the central control screen, it starts well and works for about 15 min without any problem. But after this time it suddenly stops ans doesn't try to restart. No error code on the central control screen (I don't understand some of you seem to have error codes but do you use an additionnal control unit to analyse errors?). Each time it stops, I can restart it from the central control screen but again the same problem.

Bord batteries are new. I suspect the heater internal temperature sensor but how can I be dure and solve the problem? How can I reset it?

Any advice would be of great help...

Best regards

[OldWest]

The founder and administrator of this site welcomes all languages with the translation function. Translation works fairly well.

For English only (unless you use a separate translation site), the North American Free Trade Association (NAFTA) version of the James Cook has a subforum here:

https://sprinter-source.com/forums/index.php?forums/68/

There are a lot of differences between the NAFTA version and the James Cook version.

For diagnostics, the James Cook version apparently uses the windshield central computer to give error codes by pressing various combination of buttons.

Post 10 in thread below has the instructions and codes:

https://sprinter-source.com/forums/inde ... ost-939783

Also, manuals in German here:

https://sprinter-source.com/forums/inde ... ost-429588

There are also Espar diagnostic readers as well as EDITH software on a computer which can be connected to heater but special cables may be needed as Westfalia cut off the Espar connectors for special connectors to go through the metal box.

In the USA, an OBDII vehicle reader can work as a diagnostic reader (but European vehicles may not have OBDII ports?).

https://sprinter-source.com/forums/inde ... ads/90933/

[OldWest]

As the heater works for 15 minutes or so, you might check air intake and out flow.

The three outlets should be open and not blocked (bathroom, kitchen, and behind driver seat).

The air intake is a bit tricky. There is a hole in the floor in the wall cavity behind the driver seat. The ductwork for heat sometimes droops and blocks that floor opening.

Posts 35-37 of thread below:

https://sprinter-source.com/forums/inde ... 399/page-2

There are lots of other possibilities as well. English manuals are at the website below, including Espar ones:

http://sprinterwestfalia.com/category/manuals/


Please post whatever you find. Thanks.

[Pierrot]

Thank you so much for the answer !
I will check as soon as possible what you propose.
I let you informed about the result.

This forum is such an incredible source of knowledge for our beloved James Cook !

Best regards

[Macintosh]

Hi, whats the level of gasoil in tank?

Mac

[Kasimir]

If the heater has not been used for a longer time period, set it on full force (what's that, like 30 C?) and let it run for half an hour or so. This helps to remove any kind of clogging in the combustion chamber. May help, but just guessing

[Pierrot]

Hi,

Level of gasoil is quite high. I've opened the inner side panel, it is true that the air inlet is very close to the outlet of front pilar. I tried to start with everything opened but again, stops after 15min or so. It's quite dusty there, so I will try to clean a bit before trying again. But no great hope... I think I will also contact a local eberspacher specialist (truck), for a general maintenance, because it seems that the atomizer screen and the combustion spark ignitor may be involved (some had the same symptoms and it was solved by changing them).

Best regards

[Pierrot]

Hi,

Here is a little update of my problem. Since then I have dismanteled the heater and sent it to a professional Eberspacher dealer so as to make the full mechanical service, hoping that the ECU was OK. So everything that needed to be changed has been changed : Glow plug checked, pump fuel filter new, heat exchanger new (was corroded), atomizer screen new, temp and flame sensors checked, heater fully internaly cleaned (was in quite good condition apparently), new seal.
Unfortunately after I re-installed everything again, I have the same kind of symptoms : the heater starts well, works for 5 minutes or so, reaches full power then almost stops then tries to restart, but second attempt also doesn't work (works less good because full power never reaches). If I try to restart, it works often less good because even the first cycle doesn't reach full power, as if when heater is hot is not good. I then can hear the flame being quite unstable but sure it doesn't come from the pump because I tried a second one new. Battery is new.

So I'm 100% sure that the ECU is faulty now. What kind of solution do we have? Pity to install a new Universal ECU because I will loose the central control panel utility. And it's expensive with new controler. Anyone having other solution ? Old used D4S to send to me? Seems the specific ECU of Westfalia Sprinters were not very reliable...

Best regards
Mit freundlichen Grussen

[OldWest]

1. Did heater work continuously on the bench (outside of Westfalia)?
Anyway for service center to run heater on a bench?

That way, you could narrow down problem to something on James Cook? (Air, Fuel, Temperature Sensor, Fuel lines, Fuel pump (proper angled position), etc.). Note that there are different fuel pumps (high altitude, regular).

(Fact the heater starts suggests enough battery voltage to get it going for first time.)

Then, narrow to ECU?

If you narrow to ECU, you have to be careful to choose a compatible control (not all the controls will work with the older Espar). Also, will need to do some wire splicing as Westfalia used their own connectors.

2. Fuel pump works? You mentioned that the filter was changed but was fuel pump output checked? Not just changing the fuel pump but measuring fuel flow output.

3. Fuel pump output would also presumably check the fuel pump is in proper angled or tilted position, that the hard plastic fuel lines touch each other (surrounded by rubber hose and clamps; a rubber fuel line cannot be used as apparently expands too much? So the hard plastic tube hoses must be used).

4. Could you try disconnect fuel line intake and using a separate container of diesel or kerosene? Might address any issues with fuel line in diesel tank?

Please keep us posted.

[Pierrot]

Hi,

Thanks for your reply. Actually :
1. Yes, the heater works perfectly on the bench with a universal ECU. Unfortunately cannot narrow down problem to something on James Cook (Air, Fuel, Temperature Sensor, Fuel lines, Fuel pump (proper angled position), etc.). Everything has been checked. Pump has been checked ans I have a normal second one si sure it doesn't come from the pump : I've checked the flow and it corresponds to the normal flow for such pump.
2. See 1, Unfortunately yes.
3. Unfortunately everything checked
4. I can see the flow just on the intake before the heater with a strong back light, so sure that fuel arrives properly to the heater

So can you tell me which option is available : Universal ECU with new harness and controller, something else ?

Best regards

[OldWest]

1. New ECU and Westfalia Software Program

See second post from Bullifan/Stefan.

https://forum.james-cook-freunde.de/vie ... =16&t=6288

2. In the USA, see post #31 from Wasaabi using a new ECU and D1000.

https://sprinter-source.com/forums/inde ... ost-434100


Please post whatever you find. Thanks.

[Pierrot]

Hi,

Thanks for the tips.
It seems there are at least 2 more options :

- Sending the control unit to Warmpol which may repair it
- Trying to find a 225101003701 ECU from Hella which may be a replacement while keeping central control Westfalia

Did anyone of you tried one of these ? I will ask for every possibility so as to choose best option.

Best regards

[BulliFan]

Für alle D4S geplagten, deren Steuergerät (ECU) nicht mehr funktioniert gibts gute Nachrichten. Ich habe für Pierrot eben mit Eberspächer hier in Hamburg gesprochen. Die ECU ist für knapp 300 Euro zzgl. MWSt. noch lieferbar ( Ersatzteilnummer 225101003701 ). Lieferzeit ca. 3 bis 4 Wochen.
Ich hatte das Steuergerät 2016 erneuert, seitdem keine Probleme mehr mit meiner D4S.

[Pierrot]

Thanks to Stefan, new ECU is ordered. Item number is 225101003701, normally should be plug and play for the connections, it is a replacement for the old ECU but with better electronics (Hella). This is the solution if I wanted to keep central Westfalia command panel.

They told me only 2 of these new ECU are still on the shelf at Eberspacher (so only 1 left now...). I've asked them if Eberspacher is simply stopping production or if new ones could be ordered after, I let you informed about the answer. Price including taxes is about 350€.
I also let you informed when I receive and install it, and hope it will work fine for the next 15 years or more...

Best regards

[Pierrot]

Dear guys,

Just changed the electronic control unit (ECU) of the heater and it works like a charm! ECU was received within only a few days from Eberspacher. Installation is almost plug and play, only 1 connector (for the pump) to drill because it has 3 pins instead of 2 for the original.

I must say I'm very happy because I was very unlucky with heaters in the past : among my 3 vehicles (VW T3 Westfalia, VW LT Florida, and now Mercedes James Cook), none of them had their heater functional so far when I bought them. So it feels like a miracle when the heater is working normally and regulating the temp smoothly...

It seems from the Eberspacher dealer that the production of these ECUs for James Cook is not over, so Eberspacher is still able to produce them which is a good news for our old James Cook !