Complete repair guide for the Chinook Bayside – Diesel Heater Glow Plug & Fuel Pump Service. Follow these steps to diagnose and fix the issue yourself.
Parts & Tools You’ll Need
- Webasto / Espar ceramic glow plug
- Diesel heater fuel dosing pump (12V)
- Inline diesel fuel filter
- Diesel heater LCD control panel
- Combustion chamber blower motor
- Intake & exhaust silencer kit
- Diesel fuel line silicone tubing (4mm)
- Digital multimeter (auto-ranging)
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Step-by-Step Repair Guide
Step 1: Diagnose Heater Issues and Prepare
Start by connecting your digital multimeter to the glow plug terminals to verify voltage output—you should read approximately 12V when the heater control panel is activated. Disconnect the negative battery terminal and allow the diesel heater system to cool for at least 30 minutes before proceeding with any component removal to ensure your safety.
Step 2: Remove Glow Plug and Housing
Locate the ceramic glow plug assembly mounted on the combustion chamber and carefully disconnect the electrical connector by gently prying the tab with a flathead screwdriver. Unscrew the glow plug housing using a 10mm wrench, taking care not to damage the fragile ceramic element as you extract it from the heater core.
Step 3: Replace Fuel Dosing Pump Assembly
Disconnect the fuel inlet and outlet lines from your old 12V fuel dosing pump by loosening the compression fittings—have a small container ready to catch any residual diesel fuel. Install your new fuel pump by reversing the connection process, ensuring you hand-tighten the fittings first before using your wrench to avoid cross-threading the delicate fuel lines.
Step 4: Install Fresh Inline Fuel Filter
Cut out the existing inline diesel fuel filter from the fuel line supply circuit using a utility knife or fuel line cutter to ensure clean, straight cuts. Connect your new inline filter between the fuel pump outlet and the heater intake using 4mm silicone tubing, securing each connection with stainless steel hose clamps tightened firmly but not excessively.
Step 5: Inspect Combustion Chamber and Blower
Remove the combustion chamber shroud by unbolting the four corner fasteners, then visually inspect the blower motor fan for carbon buildup or debris and clean gently with a soft brush. Test the blower motor continuity using your multimeter on the ohms setting—you should see resistance between 15-25 ohms; if readings are infinite, replace the motor assembly.
Step 6: Reassemble Heater with New Glow Plug
Thread your new ceramic glow plug into the combustion chamber housing and hand-tighten before using a 10mm wrench to snug it to approximately 15 foot-pounds of torque. Reconnect the glow plug electrical connector firmly, then reattach the combustion chamber shroud and intake/exhaust silencer kit, ensuring all gasket surfaces are clean and dry before final assembly.
Step 7: Test Complete System Functionality
Reconnect the negative battery terminal and activate your diesel heater using the LCD control panel, observing for immediate fuel pump priming sounds and glow plug ignition within 3-5 seconds. Allow the heater to run for 10 minutes while monitoring exhaust temperature with an infrared thermometer—the outlet should reach 80-100°C; if not, recheck all fuel line connections and glow plug voltage.
Recommended Parts
| Part | Link |
|---|---|
| Webasto / Espar ceramic glow plug | View on Amazon |
| Diesel heater fuel dosing pump (12V) | View on Amazon |
| Inline diesel fuel filter | View on Amazon |
| Diesel heater LCD control panel | View on Amazon |
| Combustion chamber blower motor | View on Amazon |
| Intake & exhaust silencer kit | View on Amazon |
| Diesel fuel line silicone tubing (4mm) | View on Amazon |
| Digital multimeter (auto-ranging) | View on Amazon |