Citroen DS3 A/C Evaporator leak

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vladd.alex
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Citroen DS3 A/C Evaporator leak

Post by vladd.alex »

Hello guys. Unfortunately I have some bad news from my wife’s DS3 2012 1.4 HDi just bought a few months ago. AC was not starting therefore I have been to the garage to refill the R134a. Everything great, compressor working, cold air. But same day, I have discovered a heavy smell inside the car which was refrigerant. So I assumed it is an expansion valve leakage, therefore I removed it and changed the two sealing. But no improvement, therefore again been at the garage and inject contrast substance in the installation. In a few days I have checked the entire system with an UV light and nothing appeared on the outside. Therefore I started to think about the evaporator from the dash.

Unfortunately this is the leakage origin. I figured it out by finding contrast substance in the condensation pipe which is going out from the car (under it).

My request to you is if you can help me with some documentation to replace the entire air con matrix. Unfortunately I have to remove the dash so it will be very challenging.

Thank you very much guys!
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vladd.alex
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Re: Citroen DS3 A/C Evaporator leak

Post by vladd.alex »

And one more thing, I have found a complete 6480 A9 Module with around 110£, but it is coming from a right handed car and mine is left handed. Do you think it will fit? On Service Box looks the same. Many thanks!

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GiveMeABreak
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Re: Citroen DS3 A/C Evaporator leak

Post by GiveMeABreak »

Yes the Evaporator Housing is the same for felt or right hand drive vehicles Vlad.

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Re: Citroen DS3 A/C Evaporator leak

Post by GiveMeABreak »

So as I mentioned in my email Vlad, if replacing the heater matrix, this can be done as follows:

DS3 1.4 Hdi Heater Matrix Remove & Replace

Tools
Vlad Tools.PNG
Vlad Tools.PNG (54.03 KiB) Viewed 274 times
Hose Clamps
Removing

Engine compartment side
Disconnect the battery (follow the BSI Reset / Battery Disconnect / Reconnect Procedure)

Remove:
  • The battery cover
  • The air intake duct at the air filter (DV engine)
Vlad A.PNG
Vlad B.PNG
Depressurise the cooling system.
Position the tools [4153-T] on the hoses (1).
Remove the locking clips.
Disconnect the pipes (1).

N.B.: Evacuate as much coolant as possible
from the heater matrix using an air gun placed at the inlet.
Position a receptacle to recover the coolant.
Remove:
  • The (4) bolt
  • The retention panel (3)
  • The rubber seal (2)
Left Hand Side:
Vlad C.PNG
Vlad D.PNG
Remove the pins (5).
Release: The trim under the fascia (6).
Disconnect the connector of the lamp (If necessary).
Remove: The trim under the fascia (6).
Remove bolts (7).
Unclip the trim (8) ( as "a").

Vlad E.PNG
Disconnect the connector ( as "b") (According to version).
Remove:
  • The bolts (10), (11)
  • The fixing panel of the heater matrix pipes (9)
  • The clips (12) using pliers (Type FACOM 177E.18)
Move aside the heater pipes (13).
Remove the heater matrix.
Refitting

Refit:
  • The matrix
  • The heater matrix pipes (13)
  • The clips (12) (New)
  • The heater matrix fixing panel (9)
  • The bolts (10), (11)
Connect the connector ( as "b").
Refit:
  • The rubber seal (2)
  • The retention panel (3)
  • The (4) bolt
Join the hoses (1).
Remove the tools [4153-T].
Refit:
  • The air intake duct at the air filter (engine version DV)
  • The intake resonator (engine version EP)
  • The battery cover
Reconnect the battery - follow the reconnection part of (BSI Reset / Battery Disconnect / Reconnect Procedure)
Fill and bleed the cooling system.
Check the sealing of the cooling system.

Refit:
  • The trim (8)
  • The (7) bolt
Connect the lamp connector (If necessary).

Refit:
  • The trim under the fascia (6)
  • The pins (5)
Check the operation of the heat exchanger.

vladd.alex
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Re: Citroen DS3 A/C Evaporator leak

Post by vladd.alex »

Hello Marc. Thank you very much for the nice instructions. Unfortunately in my case I can not replace the evaporator because it is integrated into the big housing, therefore I shall replace thing there. To reach the housing for replacement, the entire dashboard shall be removed. So here comes the tricky thing. I need to know what I have to remove and what to leave there e.g. steering wheel, instrument cluster, airbags, radio, display, air blowers, lacquered ornament a.s.o. For those which are really visible by the user, I would threat them with big care to avoid scratches.

Is there a possibility to buy from Citroen the instructions for 6480A9 replacement, which includes the dashboard replace?

If not, do you have instructions for the parts mentioned by me in the example?

Many thanks.

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GiveMeABreak
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Re: Citroen DS3 A/C Evaporator leak

Post by GiveMeABreak »

That part is essentially the complete heater unit housing Vlad, costs new £914.11 inc. VAT.

This involves removing the complete dashboard, centre console, BSI, heater matrix and pipes, ducting, instrument cluster, fascia, climate, audio, airbags, steering wheel controls and clock spring / steering wheel angle sensor (so that will need recallibrating after) - the lot and involves multiple procedures for each component, so an enormous task. There is no single procedure for this - it does not exist, but as I said it involves multiple procedures to remove each component and further procedures within those for the other associated parts - so is basically a complete strip down in order to get the heater unit out. That's not something I can put up here as it is too involved unfortunately and would take ages to do.

I'll send you an email shortly concerning this.

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Re: Citroen DS3 A/C Evaporator leak

Post by vladd.alex »

Many thanks Marc. This task is enormous indeed. I am wondering why did PSA thought that the heater unit is lifetime. Otherwise, why they have not made the radiators inside replaceable as single units and not complete. So sad for this. But...I have trust and I want to take over this big task on the first sunny Saturday. Tomorrow I will buy the unit which is also still fitted on a second hand car. So I will assist to the dismounting and learn step by step the procedure.

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Re: Citroen DS3 A/C Evaporator leak

Post by GiveMeABreak »

I've not heard of many that have this issue to be honest - and would expect the system to be quite reliable given that this has to go in before everything else is assembled around the heater unit. I do think you will need a good few days on this as some of the trim can take time to remove without breaking - so it is time-intensive. I suggest you take lots of camera shots as you go along so you can backtrace your steps! :)

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Re: Citroen DS3 A/C Evaporator leak

Post by vladd.alex »

Good point with the camera shots Marc. And also I am thinking to have small bags with labels for each pair of screws that I remove. In the end if it is not only a one day task it will be really difficult to remember everything. I’ve also not heard any other situation like that but as long as I have contra at substance in the condensation pipe it is obviously that the radiator is severely leaking inside. Good that I didn’t got poisoned by R134a inside after two weeks of driving and feeling that strange iron smell from the fan.

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Re: Citroen DS3 A/C Evaporator leak

Post by vladd.alex »

Good news, I have the module. I have assisted the guys to remove the dash and the module, for me it seems very complicated. After removing all the ornaments and displays, instrument clusters, central console, it was hard to remove the dash, being fixed on the reinforcement pipe with some screws mounted from the other side (from widescreen to rear side). So the guys has simply cut it. For sure I cannot do the same, therefore I would like to find out if I can remove the dash together with the reinforcement cylindrical pipe (same time). If not, it will become really hard.

For a better understanding after having the car like in the attached picture, it was almost impossible to pull the dash.
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44354BB0-3745-4C6C-9DE6-A520FE90EDAA.jpeg

vladd.alex
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Re: Citroen DS3 A/C Evaporator leak

Post by vladd.alex »

Here some pics with the module.
Attachments
7418A7AB-40C6-45C4-992A-4930D060256F.jpeg
E52B01E2-AF72-4CCC-B241-627DEBEE66AC.jpeg
EAA297DE-E030-4E6A-B755-60C192D7715F.jpeg
121AE27D-21F7-4515-9D04-9E22AECCC609.jpeg

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Re: Citroen DS3 A/C Evaporator leak

Post by admiral51 »

Hi Vladd
Good work on getting so far, however i think maybe Marc will be the one who may ( only may no promises :) ) be able to provide you with a diagram of the locating bolts for the dash.
My guess is they will have nuts on that are located in the engine bay behind the sound proofing on the bulk head.

vladd.alex
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Re: Citroen DS3 A/C Evaporator leak

Post by vladd.alex »

admiral51 wrote:
14 Mar 2020, 16:58
Hi Vladd
Good work on getting so far, however i think maybe Marc will be the one who may ( only may no promises :) ) be able to provide you with a diagram of the locating bolts for the dash.
My guess is they will have nuts on that are located in the engine bay behind the sound proofing on the bulk head.
Hi! Unfortunately there are no bolts on the engine compartiment or under the windscreen. Only hidden screws are fitted into the reinforcement pipe but mounted somehow impossible to be accessed. From citroen documentation one step is missing unfortunately. These hidden screws are not shown. I am wondering if I can remove the steering wheel column directly from the bolt close to the pedals and pull the complete dash including the reinforcement.

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Re: Citroen DS3 A/C Evaporator leak

Post by admiral51 »

Can you get some pics of the pipe and screws ?
100 eyes are better than 2 :)

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Re: Citroen DS3 A/C Evaporator leak

Post by GiveMeABreak »

Vlad - 'reinforcement pipe' - do you have any pictures of this as I cant work out what you are referring to - if you can point out the location I might be able to determine if it is any other are apart from what I have sent you.