Carado and Sunlight Priority Checklist identifies priority areas of potential flaws, incorrect installation and potential hazards. It synthesizes available information into a manageable starting point for new Carado and Sunlight owners.

At the top of the list, highlighted in red, are items critical to the health of your van.  As you go down the list there are other important items to check and get to know. Finally, at the bottom of the list, you can find items of lower immediacy.  These items are examples of personal preference of upgrades and modifications.

This list is merely a priority checklist and not a how-to guide.  It includes some links to suppliers and some examples of mods.  With that in mind, once you identify your priorities go ahead and do your own research.   You can then decide whether you need to hire someone or attempt on your own.

Sources

A lot of useful information can be found on the SUIET Hacks website as well as on groups such as Carado and Sunlight owners, Carado Axion, and Class B forum.

We thank Chris Saeger, Donna Lacey, Ervin Keczem, Riccardo Bulissimo, and Seong Jun Bae — all experienced owners — for compiling, writing, and editing the Carado and Sunlight Priority Checklist.

In addition, we would like to thank the anonymous Carado owner who identified the need for a Carado and Sunlight priority checklist when he/she filled the owners’ survey.  We hope this will ease some of the growing pains.

Carado and Sunlight Priority Checklist

CRITICAL Priority

• Check Balmar, solar, and inverter parameters and reprogram if necessary – the factory settings are flawed and may cause overcharging. Reprogramming to the correct parameters, especially the solar controller, is critical. Settings and programming guidance can be found on the SUIET Hacks website, Ks2 settings at the bottom of this post
• Coolant leak – check the rear of the underhood generator (GU) to see if the pulley is rubbing on the coolant hose. Check for damage, leaks, and loose clamps on the hose. The hose is a special version available at NationsStarterAlternator.com

High Priority

• Check underhood generator (GU) wires and bolts – examine the wiring harness as it exits the underhood generator (GU). Inspect the GU shield and spacers for cracks. Tighten all bolts. Check for cracked and rubbing wires near the black plastic shield and from the GU to the Balmar. Check if the GU shield is pinching the blue wire coming out of the plug at GU. You may need to adjust the shield with spacers and/or modify its shape.
• Check windshield/Cowl areas for leaks – water can enter the engine compartment through several entry points that need to be sealed.  Moisture in the engine compartment can cause many issues including ice buildup that may cause the alternator belt to seize. Some more information here and here
• Check how your van is wired (charge or discharge side) – there are pros and cons to either, but you need to know how the van is wired for battery management. Many recommend to rewire the solar and inverter to the charge side. You can find more information here
• Battery Revision – for best Ecotrek management, find out which rev batteries you have.  There is a sticker on each battery (H, HR, L1, L2, L1R, or L2R)

Medium Priority

• Move Balmar – the Balmar is in a location susceptible to water, snow, mud, and salt which may not be good for a sensitive electronic device. You can find an example here 
• Tighten plumbing connections – check for loose connections throughout, including behind the fridge and toilet.  Some connections were not tightened properly at manufacturing and may cause leaks.
• Check overflow hose – check the fresh water tank overflow hose for improper installation that may cause leaking inside the van. Trace the hose from the fresh water tank (you may need to move the fridge) and ensure it drains outside the van. There are a number of options in the Carado and Sunlight Owners Facebook group
• Remove white wire from underhood generator (if present) – this wire is only needed on diesel engine vehicles and could cause the Balmar to short out.  You can find more information here
• Check Serpentine Belt spare and installation tool – the GU requires a serpentine belt to run off the engine’s pulley and a special tool to install it.  Hymer supplied a spare belt and removal/installation tool. If you are missing either, you can order from NationsStarterAlternator.com (573) 334-2632. The product number for the tool is A2-0070-3 (about $20 each). The belt part number 475KG, is also available at Amazon for about $15 

Lower Priority 

• Check interior screws and bolt – tighten screws throughout the van, hinges, drawers, bug screen, and TV, etc. 
• Disengage solar – a cut-off switch could be added to prevent AGM discharge when the vehicle isn’t being used for long periods, or in freezing temperatures to prevent batteries from charging when frozen.  You can search here for some solutions, and get the switch here
• E-Guard – many owners have installed a special metal shield, the E-guard, to better protect the GU as well as the entire underside of the engine. The E-guard is available from Edge Van Works . The cost including installation is about $700
• Solar panel hail protection – some areas are more susceptible to large hail or intense storms.  Protecting your solar panels from potential damage may be prudent.   You can find more information here
• Install black tank sensor disconnect switch – most sensors give false reading after some use.  The sensor may send a signal to the toilet and it will stop flushing.  You may need to disconnect the yellow wire behind the toilet. More information here

Personal PREFERENCE

• Grille bug screen – the large spaces in the grille easily allow objects to hit the radiator and may cause punctures.  Other objects, like leaves and butterflies may plug the radiator may cause overheating
• Sumo springs – will reduce body roll and swaying. You can search for the springs for your year and chassis model here.  A rear anti sway bar can also be added for better stability

You can print a shorter PDF version: Carado and Sunlight Priority Checklist

Feel free to send us more items, or helpful links that you think should be added and we will update accordingly.

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