Ducato heater matrix replacement

[Baggydave]

HELP!!
I have a 2.8jtd, 2003 model. My heater matrix has a slight leak & I am in the process of TRYING to change it. I have almost dismantled the complete dash & undone every bolt/screw on the matrix I can find. It’s moving a bit but I cannot get it to drop.
Any ideas would be helpful.
Many thanks in advance as I’m almost at the stage of giving up.

 

[Lenny HB]

@dave newell lvs

 

[dave newell]

Sorry I can't help having never attempted to replace a matrix in a ducato.

D.

 

[chatteris]

assume you have you removed hoses and fixings under bonnet

 

[Baggydave]

Yes hoses disconnected & plastic surround removed.
I’ve just has a fresh look this morning & have concluded that it’s not possible!
Unless I cut the dash in two & take the cross member off. That’s a step too far for me.
I’ll use some k-seal & hope it stays sealed.

Thanks for the reply’s.

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[jockaneezer]

That looks a nightmare, best of luck with getting it sorted.

 

[Lenny HB]

Have you looked on youtube?
I've see reports before of people doing it so it must be oossible, sorry can't remember where I saw it.

 

[tonyidle]

Have you checked the Fiat Forum?

 

[Boringfrog]

I've replaced one twice on a LHD Ducato 1995, and didn't strip that much dash off? I think there is metal bracket you need to bend out the way before the matrix can be removed.

 

[pappajohn]

My thoughts are the dash will be fitted as a complete pre-built unit on the production line and the matrix will either be fitted to the bulkhead or the back of the dash BEFORE final assembly.
Common practise on car production lines.
In other words the whole dash needs removing.

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[joka250]

Yes hoses disconnected & plastic surround removed.
I’ve just has a fresh look this morning & have concluded that it’s not possible!
Unless I cut the dash in two & take the cross member off. That’s a step too far for me.
I’ll use some k-seal & hope it stays sealed.

Thanks for the reply’s.

I'd be very reluctant to use any form of sealant as it often leads to other problems and you get back to removing matrix. Never removed a Ducato matrix but with many I have done it's basically sit in drivers seat and remove everything in front of you except screen. Persevere and as others suggest you tube and Fiat forum.

 

[chatteris]

[QUOTE}
I’ll use some k-seal & hope it stays sealed.
.[/QUOTE]
I put K seal in my x250 that had a leaking matrix, i put 2 bottles in and it has been fine for over 5 years

 

[Baggydave]

Hi & thanks for all the advice.
I gave up & put it all back together. Thankfully everything works.
I bought some k seal from euro parts & so far all is well. No leaks at all even after a drive to wales, where we are now.

Fingers crossed.

 

[Geobhoy]

Citroen Relay, 57 plate, I pre-checked the info re my matrix but it all seems to have been pre-2006.. mine is 2007, nothing from ANY you-tube, or forum ANYWHERE seems to give a definite answer, although Pappajohn from above seems the closest to what I'm finding.. there IS no shortcut!! the blower motor can NOT be separated from the full heater assembly, so too large to slip down, slide out, wiggle, jiggle or squeeze.. I have now removed the FULL dash-top, glove boxes etc. and am now looking to remove the strengthening support, which means the steering rack needs to drop down, and hopefully the removal of the crash bar will allow the full heater assembly to LIFT up and out, although it means the control wires for blower directions will be attached, I believe the assembly was IN when at the factory, then someone fits the crash bar AFTER .. by all means tell me another way, and make sure you describe the 07 onwards.. nothing else has..

 

[Baggydave]

Hi geobhoy.
Please please keep us informed of how you get on.

I chickened out on doing mine & just used the kseal. So far all good.

Mines done over 100k now & im getting the clutch done when lockdown is over. It’s not causing problems except for the noisy thrust bearing.

dave

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[Geobhoy]

Latest on getting the matrix out and changed. all done now, as expected the re-enforcement bar DOES need to be unbolted, all wiring looms un-clipped, steering wheel and gear change columns unbolted and swung to floor, and a further support bar from floor to upper bar, it does not need to be taken out from the van, merely lifted off the brackets, sat on the passenger seat on one side, and sat on the dash at the drivers side, remove any bolts from the matrix supports, there should be loads of room to lift the full assembly out, once out the rad can be accessed by removing all the tiny screws on the heater box.. (leaving the stalks and wheel complete, (although bear in mind I cut my dash to facilitate this.. read previous posts) once unbolted it can be lifted high on the passenger side and sat on the front seat, leaving the driver side on the dash.. (NB, this is for a RHS steering wheel) you then unclip all the loom, remove the various plugs on the heater, and lift the complete assembly out in one section.. I hope to you-tube this soon, but I'd be happy to advise anyone wanting to tackle this VERY long job. 12 -14 hours one man, probably a full day if two men(or women, don't wanna appear sexist) AS stated there are NO short cuts.. just lots of nuts and bolts and screws.. Easy? no.. impossible? no.. but you DO need to be mechanically minded.. and knowledge of plug fitments, tools required, and access to tea is a boon, I would expect a garage to charge just under £1000.00, plus part at £83.00, I got mine from a company who produce this in copper/brass, not alloy, I hope to get this up on you-tube when I have time.. I reckon I could do the job again in maybe 10-11 hours on my own. and work that down to 8-9 hours

 

[joka250]

Geobhoy do you really want enough practice to get it down to 8 or 9 hours. You might get a fair bit of business.

 

[Baggydave]

Geobhoy well done. Your very brave & tenacious. I look forward to the utube video. Mines fine so far but you never know.

thanks again for the update.

 

[AngusOg]

Citroen Relay, 57 plate, I pre-checked the info re my matrix but it all seems to have been pre-2006.. mine is 2007, nothing from ANY you-tube, or forum ANYWHERE seems to give a definite answer, although Pappajohn from above seems the closest to what I'm finding.. there IS no shortcut!! the blower motor can NOT be separated from the full heater assembly, so too large to slip down, slide out, wiggle, jiggle or squeeze.. I have now removed the FULL dash-top, glove boxes etc. and am now looking to remove the strengthening support, which means the steering rack needs to drop down, and hopefully the removal of the crash bar will allow the full heater assembly to LIFT up and out, although it means the control wires for blower directions will be attached, I believe the assembly was IN when at the factory, then someone fits the crash bar AFTER .. by all means tell me another way, and make sure you describe the 07 onwards.. nothing else has..

Hi there, did you ever manage to upload a vid to you tube? Im currently taking the dash out of my ducato 250, struggling to get the top dash lifted as it seems to be clipped in the middle nearest the windscreen.

 

[Richard n Ann]

Just ordered some k seal for mine, it's used about 500ml of water over the last 2 trips.

I thought I could smell something in the heater vents on the trip before last, I though maybe it was diesel fumes or something but then it went away.
Heater matrix sounds like a job from hell. Had a good look under and round the radiator as much as I can and can't see anything. Anyway fingers crossed

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[Baggydave]

Just ordered some k seal for mine, it's used about 500ml of water over the last 2 trips.

I thought I could smell something in the heater vents on the trip before last, I though maybe it was diesel fumes or something but then it went away.
Heater matrix sounds like a job from hell. Had a good look under and round the radiator as much as I can and can't see anything. Anyway fingers crossed

My Kseal caused no further problems for the remainder of the time I owned the van, sold it a year ago. That stuff is amazing & completely recommend.

 

[Richard n Ann]

K seal has sorted it. Very good stuff, driven to Benidorm and the water level is exactly the same