The "starts and chugs to a stop" and that it was working fine last year are a couple of important data points.
Sounds like a clogged screen going into the D5 combustion chamber. If you have easy access to the D5, (may need a special tool) and can pull the glow plug out to check it and the screen, that will provide a confirmation or elimination answer.
I had the screen on our D4 clog up on this last ski trip. By keeping the thermostat low for a long period of time and especially not ramping up the heat for 5 mins before turning off the heater, the screen clogged up. I also have a feeling that the fuel additive contributed to this condition. I did not have a replacement screen, so I fully cleaned out the existing one, and it fired back up properly. In my case, I had to disassemble the whole heater. Getting a spare screen and glow plug with tool is on my to do list.
How is your hot water heater used? Where is the D5 heater located, in the cabin or below the floor? Does it run on full for 20 to 30 mins and then get shut down, or does it go to a long period of low heat before shutting down. Is there a way to allow the D5 unit to go to full heat for 5 mins before shutting off to burn off any residue?
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Ray
Beastie 3: 2002 7.3 EB Cargo: Agile TTB, CCV High Top, Custom Walk Through, Lots of stuff added. www.BlingMyRig.com
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