✓ ISO 14001 for Environmental Management
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✓ IATF 16949 for Quality Management
How Cold Start Issues Begin
Diesel can begin to cloud just below freezing and can start to gel in the upper 20s °F. Biodiesel blends can gel even earlier, between 32 °F and 40 °F, with 100% biofuel gelling above 30 °F. Add regional fuel variability and inconsistent biodiesel blend percentages from station to station, and even well-prepared fleets get caught off guard.
Operators usually see one of four warning signs before gelling begins:
- Hard starting, where the engine struggles to fire
- Loss of power under load
- Check engine light with a fuel restriction code
- Visible clouding, thickening, or discoloration of the fuel itself
DAVCO’s patented Seeing is Believing® clear cover provides invaluable visible insight into your fuel system. Operators can spot clouding, wax suspension, or air bubbles forming inside the cover before the fuel ever reaches the engine. When the fuel level rises to the top of the filter and appears full of wax, that’s the unmistakable signature of cold weather gelling.
Heat at the Filter, Not Chemicals in the Tank
Fuel filter heater warms the fuel right where it matters: just before it reaches the engine. DAVCO’s approach is uniquely efficient. Rather than trying to heat 100–300 gallons of fuel sitting in the tank, DAVCO heated units heat only the small 2-to-4-gallon “window” of fuel that flows through the processor before reaching the injection system. That targeted window uses far less energy and warms fuel far faster than any tank heater can.
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Choose the Right Heated Fuel Filter for Your Application
DAVCO offers four fuel heater options matched to how and where your equipment operates.
12VDC and 24VDC Pre-Heaters
There are various configurations of electric pre-heaters and thermoswitches available for the Fuel Pro® and Diesel Pro® lines.
These include 12VDC pre-heaters, 24VDC pre-heaters, and combination pre-heater thermoswitches. The voltage and wattage ratings are stamped either on the sheath or the hex of each component for identification. To find the correct heater for your fuel processor, visit the Service Parts page.
120VAC Overnight Heater
Install a 120VAC plug-in pre-heater to prevent fuel gelling due to overnight cold weather. The 120VAC watt overnight heater warms fuel when your truck is sitting and potentially freezing on cold winter nights. Warm fuel is less apt to gel and plug filters.
The DAVCO 120VAC pre-heater plugs into the same power outlet used for engine block heaters. If your truck already has block heaters or engine heaters which connect to 120VAC plugs, you may be able to wire the DAVCO pre-heater into that same wiring harness using a“Y” cord.
Return Fuel Heat (Fuel Pro®)
Return fuel heat is available for Fuel Pro® 388 and the Fuel Pro® 499 models on Navistar trucks.
How does return fuel heat work? Unfiltered, cold fuel flows from the fuel tank into the body of the Fuel Pro®. Heated fuel is routed into the fuel manifold. Returned warm fuel from the engine flows into the housing when the thermostat senses a fuel temperature below 95 °F.
All returned warm fuel from the engine flows back to the tank when the thermostat senses a fuel temperature above 115 °F. Warmed fuel blends with cold fuel and is sent through the filter. To determine the correct number for your application, refer to the OEM Order Codes or call Customer Service at 866-499-6602.
Coolant Heat (Fuel Pro®)
How does coolant heat work? Unfiltered, cold fuel flows from the fuel tank into the body of the Fuel Pro®. Coolant heat is routed through the coolant manifold. The body of the Fuel Pro® is warmed by the coolant and the heat is transferred into the fuel. The warmed fuel passes through the filter. The warmed, filtered fuel is sent to the engine. The coolant and the fuel paths are separate and there is no contact.
The Fuel Pro® 382 and Fuel Pro® 387 coolant heat models have an extended bottom plate for the radiator, thermovalve, and fluid connections. To determine the correct number for your application, refer to the OEM order codes or call customer service at 866-499-6602.
Cold Weather Filtration Best Practices
A heated fuel filter is the foundation, but a few additional steps will help protect your fleet through winter:
- Use the correct filter micron rating. Never install a larger micron filter to “extend life,” because it can void engine warranties and damage injection systems. Refer to the filter options page to find the right filter for your application.
- Drain water from tanks and lines. A Shop Pro® is the recommended tool for tanks without drain ports. Watch for low spots in fuel lines where water can collect and freeze.
- Keep tanks above the half-full mark to minimize condensation.
- Drain water from the Fuel Pro® or Diesel Pro®.
- Run a battery load test before cold weather sets in.
- A 120VAC heater works best when plugged in while the engine is still warm.
Cold Weather Solutions Literature
DIAGNOSTICS WITH THE SEEING IS BELIEVING® CLEAR COVER
DAVCO’s patented clear cover allows you to easily see inside your fuel water separator and makes diagnostics a breeze. Learn more here.
Download Product LiteratureCoolant Heat Upgrades and Installation Fittings
Adding on a coolant heater for cold weather? Need to know more about what type of fittings you need? Click here to learn more!
Download Product LiteratureHeater Testing
Having an issue with a diesel fuel filter heater? Learn more about how to diagnose and treat.
Download Product LiteratureFuel Filter Heater FAQ
What temperature does diesel fuel gel?
Standard #2 diesel can begin to cloud near 32 °F and can gel in the upper 20s °F. Biodiesel blends are more sensitive. B20 blends can start gelling between 32 °F and 40 °F, and pure biodiesel (B100) may gel above 30 °F. The exact diesel gelling temperature varies by fuel source, additive package, and regional blend percentage.
How do fuel filter heaters work?
A fuel filter heater warms diesel fuel just before it passes through the filter element. DAVCO units use electric pre-heaters (12VDC, 24VDC) 120V overnight heater or fluid heat (engine coolant or return fuel) to raise the fuel temperature above its gel point. By heating only the 2-to-4-gallon window of fuel flowing through the processor, DAVCO systems use far less energy than tank-mounted heaters.
Can I add a heater to my existing DAVCO unit?
Yes. Electric pre-heaters, 120VAC overnight heaters, and coolant heat kits can be added to most Fuel Pro® and Diesel Pro® models. Visit the Service Parts page for the correct heater for your model, or call customer service at 866-499-6602 for assistance.
Do I still need fuel additives with a heated fuel filter?
A heated fuel filter addresses the root cause of gelling – cold fuel reaching the filter – so many fleets reduce or eliminate additive use after installing DAVCO heated units. However, additives can still help in extreme conditions or when fuel quality is uncertain. DAVCO’s Seeing Is Believing® clear cover lets you monitor fuel condition and decide based on what you see.