Refrigerant Leak inside Delanair Climate Control Unit

[smudge56]

Need some guidance - my 1996 4.0ltr Celebration is leaking refrigerant - the dye used in the gas is very evident at the condensate outlets underneath the car as it is dripping onto exhaust pipe - my conclusion is that the evaporator sitting next to the heater matrix is a potential culprit or indeed the feeds in don't know at this point - has anyone heard of a similar experience encountered by others? I had the system vacuum tested and refilled (it was empty when I bought the car) and within a week the aircon was no longer blowing cold air - there is a 'orrible stink when you first switch the blowers on which disappeared when the system was blowing cold air but the initial smell is not pleasant - there is no loss of coolant. Any help advice welcome - thanks - Steve

[davidr]

I'm sorry to say that this is a fairly common failure on the late cars. I'm even sorrier to say that it's not an easy fix either as it involves taking the whole of the dash out to get at the climate unit.
Sorry!

[smudge56]

Thanks David - is this something the average enthusiast could tackle? Or is it down to the Jag specialist with ones wallet wide open? Appreciate any guidance on how to do it and what parts are needed.......
Steve

[davidr]

The common scenario is the evaporator leaking. Taking the dash out is a time consuming job but not beyond the scope of a chap who's sensible with a set of spanners. You'll need to practically strip the interior including the front seats, centre console and the entire fascia. With time, space and a methodical approach it's perfectly feasible to do it at home but you will need space to store the trim etc.
Take care as you pull everything apart and take plenty of notes and pictures to help you remember where everything goes when you put it back.
The only thing that I can think of that needs a special tool is the drivers airbag. There is an arming pin that needs to be withdrawn to disarm the unit. It needs a special D shaped tool but you can make that by flattening some tube.
It's a long job so paying someone by the hour will add up. If you can do it yourself you will save a fortune and gain quite a sense of achievement!

[smudge56]

Thanks David - a job for later in the year I think - hope I get it right....will let you know how it all goes
Cheers
Steve