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Please click here to see an example of how to fit the Bio-Power Heat Exchanger.

INSTALLATION
The heat-exchanger kit contains the following items:
· The heat exchanger
· A length of flexible non-rubber fuel pipe
· 2 large jubilee clips for the water hose connections
· 2 small clips for the fuel connections
· Cable ties
The following tools will be required:
· A screwdriver to open and close the Jubilee clips
· A small spanner
· A mole grip or pliers to open and withdraw fuel lines
· A junior hacksaw
· A sharp Stanley type knife
· A pencil
You will also need:
· A means of collecting coolant water
· Replacement radiator anti-freeze or rust inhibitor (if used)


The electric heater kit contains the following items:
· The electric heater, which is prewired
· An electric fuse holder and fuse
· A length of flexible non-rubber fuel pipe
· 2 small clips for the fuel connections
· Cable ties
The following tools will be required:
· A screwdriver to open and close the Jubilee clips
· A spanner to make a electrical connection to battery, starter motor or alternator terminal

You may also need:
· Some extra length of automotive 5amp and 20amp cableto fit your situation
· Electrical connectors.

Please read these instructions carefully before fitting your heat exchanger
Procedure for fitting the Bio-Power Heat Exchanger

A. Open the engine compartment and identify the fuel lines and the water hoses. Follow the fuel supply line from the fuel tank, to the fuel filter and then to the injector pump. You will then find a second fuel line that collects the return fuel from the injectors and the injector pump and takes this fuel back to the fuel tank. Unlike petrol engines, the fuel system in a diesel circulates. Next follow the water coolant circuit. There will be a large diameter hose from the head of the engine to the top of the radiator, and a smaller hose from the lower part of the radiator to the water pump. Elsewhere on the engine there will be another water circuit to provide hot water to the cab heater, and there may also be a connection to an oil cooler.

B. The heat exchanger unit is normally placed in the main hot water circuit between the engine and the top of the radiator. Position the unit in the engine space alongside the existing water hose to find a suitable position. Mark the hose where cuts must be made into the hose to allow fitting. Drain the radiator system. Remove the unit and cut the hose with a junior hacksaw or Stanley knife. Clean the ends with a Stanley knife. Slide the large Jubilee clips over the hose ends , and then slide the hose ends over the ends of the large diameter pipe of the unit. The direction of flow through the unit can be either way. Do not tighten the jubilee clips at this stage, but just close enough to stop the unit falling off. Some household soap may be needed to help slide the hose ends over the large copper pipes of the heat exchanger.
If your vehicle is fitted with a non-heated fuel filter please proceed straight to section D.

C. If your vehicle is fitted with a heated fuel filter, locate the fuel pipe that runs from the fuel filter to the injector pump. This pipe will have to be fitted so it runs from the filter to the end of the heat exchanger nearest to the radiator. Slide one of the small clips over a suitable length of fuel pipe (cut from the fuel pipe supplied in the kit) and push the fuel pipe onto the heat exchanger’s small copper pipe nearest to the radiator. There is often a section of clear pipe like a window and this should be positioned so it can be viewed easily. Finally the connection is made from the injector pump to the small copper pipe of the heat exchanger unit that is nearest to the engine. If necessary an additional section of fuel pipe may have to be added to achieve this connection. If everything seems secure then the jubilee clips can now be tightened and the radiator system re-filled with water.
Proceed straight to section E if your vehicle is fitted with a heated fuel filter.

D. If your vehicle is fitted with a non-heated fuel filter, locate the fuel pipe that runs from the fuel tank to the fuel filter. This pipe will have to be fitted so it runs from the tank to the end of the heat exchanger nearest to the radiator. Slide one of the small clips over a suitable length of fuel pipe (cut from the fuel pipe supplied in the kit) and push the fuel pipe onto the heat exchanger’s small copper pipe nearest to the radiator. Finally the connection is made from the fuel filter to the small copper pipe of the heat exchanger unit that is nearest to the engine. If necessary an additional section of fuel pipe may have to be added to achieve this connection. If everything seems secure, tighten the jubilee clips and re-fill the coolant system with water/antifreeze. Ensure that any air locks in the coolant system are removed. Should the heat-exchanger remain cool, whilst the engine is warm and running, you’ve got an air lock. This needs to be cleared otherwise the engine will overheat.

E. Before starting the engine it is best to prime the fuel system to remove any air pockets from the fuel line. This is easy to achieve if there is a bellows type fuel line pump or a Peugeot hand operated fuel pump. Slightly open the banjo that secures the fuel supply to the injector pump (or undo the pipe connection at the injector pump) to let out any trapped air, and operate the pump. Notice that the plunger type of pump has to be unscrewed to free from the fuel filter chassis. Operate the pump until no more bubbles come from the opened banjo, and only clear fuel. When you are satisfied that the fuel line is properly flooded you can tighten the banjo carefully.

F. Now try starting the engine. It may take a little while for the fuel to pull through and any air locks to pass through.
Remember that the heat exchanger will only have an effect once the unit is well warmed up. This may take about 10 minutes or 5 miles of driving.

G. When you are satisfied with the operation of the unit, check that there are no leaks, and check that the unit is not touching any moving parts of the engine or hot parts near the manifold or the radiator fan. Tighten all the jubilee clips and finally secure the unit using the cable ties, and secure the fuel lines.
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All bio-power parts, heat-exchangers and heaters are protected by copyright and may not be produced or copied without express permission from the designer and copyright holder.