Ultimate Guide to Van Heating and Cooling Systems

Managing temperature in your van is crucial for comfort, whether you're tackling freezing winters or scorching summers. Here's a quick breakdown of what you need to know:

Heating Options: Diesel heaters (fuel-efficient, great for cold climates), propane heaters (quiet, low maintenance), and electric heaters (simple but power-hungry).
Cooling Options: Roof fans (affordable, effective for airflow), portable AC units (good for temporary relief), and roof AC systems (powerful but require strong electrical setups).
Insulation: Essential for temperature control. Popular materials include recycled plastic, polyiso board, and 3M Thinsulate.
Ventilation: Roof fans, cross-ventilation, and insulated window covers improve airflow and reduce condensation.
DIY vs. Professional Installation: Diesel heaters are DIY-friendly with basic tools and skills, but complex systems like hydronic heaters are best left to professionals.

Quick Comparison

System	Best For	Cost	Power Needs	Key Features
Diesel Heaters	Cold climates	$1,650–$1,954	Low fuel consumption	Reliable, works at high altitudes
Propane Heaters	Quiet operation	Varies	Minimal	Cleaner emissions, low maintenance
Electric Heaters	Mild climates	Varies	High power required	Easy to use but drains batteries quickly
Roof Fans	Basic cooling	~$300	Low	Affordable, improves airflow
Roof AC Systems	Hot climates	$2,969+	High	Powerful cooling, requires strong batteries

For the best results, pair heating or cooling systems with proper insulation and airflow management. Whether you're a DIY enthusiast or prefer professional help, these tips will help you create a comfortable van setup for any season.

Van Conversion: Heating, Cooling, and Temperature Control

Van Heating Systems

A good heating system is essential for staying comfortable no matter the season. Picking the right heating option for your Sprinter van depends on your setup and travel needs. The main choices - diesel, propane, and electric heaters - each have their own perks.

Diesel Heaters

Diesel heaters connect directly to your van's fuel tank, making them a convenient and efficient option. They can provide 22–24 hours of heat per gallon of fuel.

Feature	Espar Airtronic AS3 D2L	Webasto Air Top 2000 STC
Price	$1,650.00	$1,954.00
Power Output	2kW	2kW
Controller	EasyStart Pro	SmarTemp 3.0 BT
Best For	Reliable performance	Compact design

It's important to choose the right size: 2kW heaters are great for mild climates, while 4kW models are better suited for colder regions.

Propane Heaters

Propane heaters are known for their quiet operation and lower emissions compared to diesel systems. They offer several benefits:

Fuel efficiency: Consumes about 1 lb of propane every 3 hours.
Cleaner emissions: Produces fewer pollutants than diesel heaters.
Low maintenance: Requires servicing less often than diesel models.
Altitude performance: Works well at various elevations without needing adjustments.

Electric Heaters

Electric heaters are straightforward to use but require a strong electrical system. You’ll need to consider factors like battery capacity, power consumption, charging sources, and your climate. For installations over 3 feet from the battery, use 10AWG wire to prevent voltage drops.

For more complicated setups involving fuel lines or electrical and ventilation systems, professional services - such as those offered by Sandy Vans - can help ensure everything is installed correctly.

Van Cooling Systems

Keeping your van cool during warm weather is essential for comfort. According to surveys, 52% of van owners use roof fans, while only 11% have full AC systems installed. Let’s break down the best cooling options available.

Roof Fans

Roof fans are the go-to choice for many van owners because they’re affordable and effective. They create airflow by pulling hot air out and bringing cooler air in. Pairing these fans with floor-level vents can enhance airflow and cooling.

Roof fans are especially useful for:

Getting rid of cooking smells and moisture
Reducing condensation
Basic temperature control
Running on low power

If you find roof fans aren’t enough during intense heat, a portable AC unit can provide extra relief.

Mobile AC Units

Portable AC units are a great backup for hotter days. These units offer temporary cooling and are easy to move around the van. However, they do require proper venting for the exhaust.

When choosing a portable AC, consider:

Power Needs: They usually require a lot of power to run effectively.
Space: These units take up floor space, which can be a concern in smaller vans.
Ventilation: You’ll need a window or vent for the exhaust hose.
Portability: Their mobility makes them easy to relocate within the van.

Roof AC Systems

For top-notch cooling, roof-mounted AC systems are the best option. The Dometic RTX 2000, priced at $2,969.00, is a standout model. Here’s a comparison of two popular systems:

Feature	Dometic RTX 2000	Fresair Evaporative Cooler
Cooling Capacity	6,824 BTU	15-20°F below ambient
Power Requirements	500ah lithium recommended	Less than 10A/h
Temperature Drop	25-40°F below ambient	15-20°F below ambient
Humidity Performance	Works in all conditions	Limited in high humidity

Roof AC systems require strong roof support, reliable power (like lithium batteries or shore power), and professional installation. Keep in mind they also add height to your van, which could be a factor for clearance.

To get the best results, combine roof AC systems with proper insulation and window coverings. These systems are ideal for full-time van lifers in hot climates who have consistent access to power.

Insulation and Air Flow

Insulation Types

Keeping your van at a comfortable temperature starts with good insulation. A 2023 study revealed that recycled plastic insulation was the top choice, used in 41% of vans, followed by polyiso board at 21%.

Here’s a quick comparison of popular insulation materials and their costs:

Material	R-Value Per Inch	Cost Per Sq Ft	Best Use Case
MegaZorbe Pro	4.16	$9.38	High-performance areas
Luxury Liner Pro	4.45	$7.00	Premium sound/heat barrier
MegaZorbe	4.16	$6.65	General purpose
EcoVerb Roll	4.0	$3.25	Budget-friendly option
Heat Wave Pro	4.0	$2.75	Cost-effective solution

Make sure to cover all interior surfaces with materials that provide enough R-value for insulation. Shane Monks O'Byrne, founder of The Van Conversion, shares this advice:

"I recommend using Polyiso foam board fixed with insulation stick pins for most of the big exposed areas in your van... For tight areas and air gaps, I recommend using 3M Thinsulate or Hempitecture HempWool."

Window Protection

Windows are a common source of heat loss or gain, so insulating them is key. Here are some options:

Sprinter-specific insulation sets: Designed for 2007–2021 models, priced between $69.95 and $164.95.
Front window sets: Tailored for 2019+ Sprinters, costing $149.95.
Insulating curtains: Ranging from $125.00 to $380.00 per pair.

For example, during the winter of 2022–23, Ski Burrito managed to keep their van's interior at 60–65°F, even in temperatures as low as -5 to -10°F, by using window covers and sealing drafts.

Once your windows are insulated, improving airflow can take temperature control to the next level.

Air Flow Management

Good airflow is essential for managing temperature and moisture. With the right setup, you can reduce the need for air conditioning while staying comfortable.

Here are two key strategies for better airflow:

Install multiple ventilation points: Position windows on opposite sides of the van to create cross-ventilation.
Use reversible roof fans: These allow you to control both intake and exhaust airflow.

For the best results, consider installing two ceiling fans - one for intake and one for exhaust. This setup provides better airflow than a single fan and uses less power than traditional AC units.

Setup Options: Self-Install vs Professional

DIY Requirements

Installing a diesel heater yourself typically takes around 10 hours.

Here’s what you’ll need:

Tools: Metric socket set with ratchet, drill with specific hole saws (1-⅛ or 1-¼ inch), crimping tools, panel beating tools (or a 2x4 and hammer), and a specialized blade for cutting fuel lines.
Skills: Basic knowledge of electrical wiring, comfort with drilling and cutting, an understanding of fuel line routing, and experience working under vehicles.

Professional Installation

Hiring a professional comes at a cost. Expect to pay over $1,000 for air heaters and between $4,000–$6,000 for hydronic systems.

Installation Type	Benefits	Challenges
Air Heaters	More affordable, simpler setup	Requires tapping into the fuel tank
Hydronic Heaters	More efficient, supports multiple zones	Involves complex coolant loop setup

According to Engineers Who Van Life, with patience and careful reading of the manual, air heaters can be installed by most DIYers.

If you’re leaning toward professional help, keep reading for details on specialized services.

Sandy Vans Services

Sandy Vans

Looking for expert installation? Sandy Vans offers professional heating and cooling system setups specifically for Sprinter vans. Their services include diesel heater installation, Maxxair fan deluxe integration, and custom window installations for better airflow.

Their technicians ensure precise installation and thoroughly test every system for reliability.

When deciding between DIY and professional installation, think about your technical skills, the time you can commit, and the complexity of your system. While air heaters are often manageable for DIY enthusiasts, systems like hydronic heaters are better suited for professional handling.

System Care and Problem-Solving

Regular Maintenance

Keep your van's heating and cooling systems running smoothly with regular checkups:

Monthly Tasks:

Clean vents and filters to maintain proper airflow.
Check coolant levels and refill if needed.
Inspect the radiator and hoses for any signs of wear or damage.
Look over wiring harnesses for possible corrosion.

Annual Tasks:

Use a hose to clean condenser coils.
Schedule a transmission inspection.
Test heating and cooling components for functionality.
Examine the wiring systems thoroughly.

Staying on top of these tasks can help prevent many issues, though some problems might still need troubleshooting.

Common Problems and Fixes

Even with regular maintenance, issues can crop up. Here's a quick guide to common problems and how to address them:

Issue	Possible Cause	Solution
AC blowing warm air	Low refrigerant	Recharge the AC system.
No heat	Heater core problems	Inspect and clean the heater core.
Uneven temperature	Blocked vents	Clear obstructions from vents.
Strange noises	Loose components	Get a professional inspection.
Poor performance	Clogged fuel filter	Replace the fuel filter as needed.

These fixes work hand-in-hand with the maintenance steps mentioned earlier.

When to Call a Pro

Some issues are best left to professionals. Reach out for help if you encounter any of the following:

Water leaking from the overflow pan.
Clogs in the condensate line.
Strange noises like hissing, banging, or rattling.
Motor failures unrelated to breaker problems.
A sudden and unexplained spike in energy usage.

For specialized repairs - particularly in custom systems - turn to experts like Sandy Vans. Their technicians are equipped to handle advanced HVAC challenges. If your AC still isn’t cooling after checking filters and airflow, it’s time to get professional assistance. Persistent issues or multiple warning signs should never be ignored.

Final Tips for Van Temperature Control

To keep your van at the perfect temperature, pick a system that matches your insulation and climate. For example, 2kW units are great for mild conditions, while 4kW systems handle colder weather. Avoid going too big with options like 8kW models - they can be overkill and inefficient.

Fuel and Power Management

Modern diesel heaters are fuel-efficient, using just 0.1–0.5 liters per hour. That means a single gallon can last anywhere from 20 to 50 hours. If you're running power-hungry AC units, make sure your electrical system can handle the load.

Smart Installation Choices

The right setup and location can make a big difference. Installing a diesel heater near the passenger seat is a popular choice for efficiency. Here are some recommended setups based on climate:

Climate Type	Recommended Setup	Key Components
Mild Climate	Basic Package	2kW Diesel Heater + Roof Fan
Variable Weather	Mid-Range Setup	4kW Diesel Heater + Maxxair Fan + Insulated Curtains
Extreme Conditions	Premium Package	Webasto Air Top 2000 STC + AC Unit + Full Insulation

These setups work well whether you're tackling the project yourself or hiring a pro.

Professional Installation Benefits

Hiring experts, like Sandy Vans, ensures precise installation and includes post-installation support to optimize your system's performance.

Year-Round Maintenance Tips

Keep your system running smoothly with these tips:

Run diesel heaters occasionally during warm months to prevent fuel gelling.
Use clear window tint to cut down on heat while driving.
Maintain good ventilation to avoid condensation buildup.

For more complex setups or upgrades, professional help is a smart move. Companies like Sandy Vans offer full installation packages, covering everything from diesel heaters to ventilation fans and complete climate control solutions.