Photographs are a mixture of overhauls of two different D1LCC heaters plus some additional photographs taken much later. This explains why the pictures have continuity errors.
The D1LC and D3LC models have much of the electronics outside the case but servicing is similar, the 24 volt model also has an additional glowpin resistor inside the case.
Here the pump, loom and controller were removed with the heater so it could be bench tested before replacing. If preferred the heater can be removed leaving these in place.
The exhaust port is badly corroded.
Very obvious why this D1LCC heater failed, needed a service. We have never seen an exhaust port with more solid carbon. The dark stain is penetrating oil applied to the fixing stud nuts. Do not replace nuts and locking washers with nylock nuts, the nylon can melt. Replacement studs sold on Ebay sometimes have no nuts.
Release the hood by lifting clear of the pips.
Undo the cable cover screw. You usually need a hex key but this screw has been replaced.
Turn and wiggle the air inlet grille to remove it.
Remove the glowpin wiring nut, its connector is a single part. Tip:- fit the nut back onto the glowpin so it does not get lost. Press in the plug retaining latch, the plug is usually very tight and here a screwdriver was needed to ease it out by levering on the plastic protrusions by my thumb.
Remove the plastic rivets. With solid head rivets two chisels can lever them out undamaged. Ones with a central pin can be cut off or the pin driven inside, they are usually not reusable.
Replacements are available on Ebay.
Rear side view
This exhaust outlet is very badly corroded,
it should be same length as the inlet pipe.
Remove the D1LCC case.
An Eberspacher D3LCC heater has two additional metal plates on the burner assembly (not shown).
Bottom - Combustion air inlet, Fuel inlet, Exhaust outlet.
Glowpin top, ECU on right.
Flame sensor left, overheat sensor middle left.
Click on images for better quality.
Disconnect the fan and two sensor cables from the ECU.
Lift the retaining latch, arrowed, and slide out the ECU.
Remove the 4 crosshead screws securing the blower unit. Check the condition of the gasket, usually it can be reused.
Remove the 2 screws securing the combustion chamber cover. Ensure the screwdriver bit is in good condition and is the correct size as these screws can become very tight.
1 Disassembling the Eberspacher D1LCC heater.
Page 2 continues with the examination, cleaning and reassembling.