Hi,

I'm looking for advice on an A/C repair for a 2005 2.8 JTD.

The system has leaked gas from within the first year after it was purchased new in 2006. We were told by the dealer (and later by Fiat head office in Australia) that the problem was the service valves which were failing and that they weren't a warrantable item. After several valve replaces regasses, arguments with the dealer and then head office, we gave up. Warranty period is long gone now.

The vehicle has been without A/C for the past five years apart from a few attempts when we have taken it to A/C repairers to try and sort the problem out. They've all failed, but a recent attempt has resulted in the evaporator being identified as the problem. A replacement from Fiat has been quoted at $2000, but the repairer is going to see if some other (less expensive) brand might be compatible.

So, does anyone have experience at getting at the evaporator (through the dash I gather) or any info on the dimensions of the component itself?

Thanks in advance.

Bill.

Hi Bill
Replacing the evaporator requires for complete removal of the dash as then the whole assembly has to be split to replace the evaporator &/or heater matrix. Our 244 had the complete heater, A/C evaporator replaced under warranty & they had to remove the dash assembly to get at it.
See attached pics from the WSM, the evaporator is marked 1 the pic on the right, the other core is the heater matrix (1 in middle pic) so from these pics the evaporator is laying on the bottom with the heater core above it, as physically the fan assembly is located right behind the lower passenger glove/storage box. Will be investigating this further on our Ducato so will get back with more info.
Hope that helps
Cheers freespirit

Edit
Sorry, the pictures changed position after posting - the evaporator (1) is in the bottom picture, the one on the right with line marked as 1 is pointing to the heater core.
Cheers

Thanks for the prompt and detailed response FreeSpirit. Really appreciate it, and keen to know anything else you find in your Ducato.

Cheers,

Bill.

Bill
Sorry I have been so long to reply.
Have just had a further look at our air con & it appears that those diagrams are completely different to what is fitted to our Aussie model even though that is for LHD when you look at them, I would have thought that the mirror reverse would apply to ours.
Those pics look as if the evaporator & heater are mounted one above the other in a horizontal plane, but when looking further on our model through the hole the resistor mounts in, the heater matrix is vertically mounted in our model & as to where the evaporator is I have yet to find?
The pipes from the compressor etc come through the firewall to the far left of the Heater/A/C assembly @ 8.0 o'clock on the round moulding where the fan is enclosed, so maybe the evaporator is directly in front of where the fan is mounted?
Thought I might see more if I removed the fan assembly itself, but guess what there is a metal bracket (which I initially thought was bolted) "spot welded" to the main support right behind it which is part of the dashboard support member.
I do remember the lady at the Fiat place saying that these A/C have been retrofitted out here in Australia by Ateco, who was the Fiat importer.
Have you gone any further with yours since your last post?
Have not given up yet! Will get back again
Cheers FreeSpirit

Hi Bill
The vertical core I could see through the fan resistor hole that I initially thought was the heater is in fact the evaporator & unlike in the picture above is like a "normal" radiator. The A/C pipes come through the firewall on the far left of the heater assembly then cross in front of the fan & under the main air intake to where there are two threaded unions on the Heater,A/C assembly itself just to the right & forward of the fan & directly below where the air/recirculate door activation cable is located, these pipes then have two threaded unions to connect to the evaporator itself.
The heater matrix core appears to be located more over on the drivers side of the Heater,A/C assembly, as the pipes come through the firewall just to the left (passengers side) of vehicle centreline, whether the core is vertical or horizontally mounted I cannot tell?
Hope that helps somewhat, I have found replacement evaporators for sale in the UK.
Cheers FreeSpirit

Hi FreeSpirit,

Thanks for looking into this so thoroughly. I haven't done any investigating on mine yet as it's a work vehicle and I need to schedule the down time, but your info will surely come in handy.

Could you put me in the direction of the replacement evaporators in the UK?

Cheers,

Bill.

Hi Bill
One of the replacement evaporator/s I found after a quick look are actually located in Germany & the one I found on eBay is in the US (listed for a Peugeot Boxer) & another in the UK but either would still be far cheaper (less 25%) than what Fiat quoted ($2000) even with the ripoff postage costs.
There is no guarantee that these are the exact evaporator for the 244 Ducato as their must be more than one type of A/C fitted to the Ducato, but those pics & diagrams (with dimensions) look similar but it is hard to tell from the bit I can see upside down with a dentists mirror !
From what I can see with the mirror they look similar as far as the pipes go & maybe from the dimensions you might source a aftermarket replacement in Australia.
There is always the option of second hand units from wreckers.
Also there is always the possibility that the "leak" could be at one of the unions where the pipes join the evaporator.
Attached is a picture I found from a wrecker on the net which appears to be the same unit as our A/C where I have indicated locations of various parts & of the evaporators, looking at all this for my own info about the Ducato, but might help someone else.
http://www.pag-automotive.com/produ...conditioning-fiat-ducato-box-244-jtd-p-134650
& the one on eBay in the US which is listed for a Peugeot Boxer is -
http://www.ebay.com.au/itm/29054090...X:IT&_trksid=p3984.m1423.l2649#ht_1087wt_1222
http://www.mister-auto.co.uk/en/eva...ed-chassis-244-2-8-jtd-128hp_v16740_g471.html - not sure if post to Oz
Cheers