Today we decided to answer in depth one of the most commonly asked questions – what‘s included in the Espar heater kit? There are lots of bits and pieces listed in the manual, but where are they in the actual box? We will try to clear things up and make it easier to prepare for the installation or just check to make sure everything’s there.

Please note that the installation kit we will be looking at - the Espar Aitronic S2 and M2, come factory sealed. In some cases, we may open it if we want to add some additional items to fulfill your order and ensure it is not damaged in transit.

Notes and preparation

Installation kits are assembled with the highest attention to detail, quality and control standards. Thus you can rest assured that everything will be included in the Espar box. However on the off chance something is missing you have this list to double check. Make sure to take care when opening the box and keep everything in one place. It often happens that bits and pieces get lost or damaged when the workspace is not properly organized.

We highly recommend using the Espar installation kit as a box for all the spare parts during your Airtronic installation. Any packaging should be open over this box to minimize the chance anything gets lost. Make sure to set aside items that are unsealed and opened, as smaller pieces might fall or get stuck in bigger items.

Let‘s get started

Below you can find an exploded drawing of all components included in the standard Espar Airtronic installation kit. You can find the same drawing in the Airtronic Technical manual, together with a full list of parts included in the universal installation kit 252720800000.

Please note this installation kit comes with all S2 and M2 heaters ( D2L, D4L, D4R and B4L).

Big Items

So first of all, let‘s start with the big items in the Airtronic Installation kit:

Figure 22.: Cable harness – main harness that plugs into the heater, controller and fuel metering pump.

Figure 12.: Fuel line – this is a fuel line for the Espar unit. The ID (inner diameter) is now the same on both ends of the fuel pump, where in the old units, these were different.

Figure 21.: Exhaust muffler / silencer – essential item included in every Installation kit.

Figure 7 / 25.: Exhaust hose – Figure 7 can be extended. Please note that the total length of the hose should not exceed 2 meters or 6.6 feet.

Figure 8.: Air intake hose – this can be cut to fit, but to a length of no less than 20 centimeters or 0.66 feet.

These are all of the loose bits in the kit, but since they are quite bulky, the chance of losing any of them is very small.

Items in Bags

BAG 22.1000.50.0300 contains Figure 10.: Fuel pump bracket- this is a rubber bracket for noise reduction and additional surface protection.

BAG 22.9000.09.0165 contains Figure 9.: Cable ties – used to fix loose cables to the vehicle body or to tie multiple cables together.

BAG 22.9000.09.0163 contains:

• Rubber Fuel line connections
• Fuel line connectors – T piece
• Exhaust Muffler Silencer bracket – used with Figure21.
• Metal Fuel pump bracket – Used with Figure 10.
• Air intake hose end cap – Used on Figure 8.

BAG 22.900.30.2720 Figure 5.: Please note that cables from this bag are placed inside of the installation kit as loose cables. This bag contains the FUSE BOX, Electrical connections and most importantly, the FUEL PUMP and the Electrical plug that connects to the fuel pump and Figure 22.

Item Bags not shown on the exploded drawing

These following bags are not explicitly shown on the Espar Airtronic exploded drawing, but they are included in the box and are essential for the installation.

BAG 22.9000.09.0161 contains fuel hose / connection clamps. Contains 9mm, 11mm and 14m clamps.

BAG 22.9000.09.0162 contains 3 different types of clamps for securing the Airtronics exhaust system:

• 1 Clamp for air intake hose;
• 2 Holders for hoses;
• 1 fuel hose clamp.

BAG 25.2069.80.07.00 Contains Bolts, nuts, washers and screws for all of the bits highlighted above.