Description
Filter Box with Water–Air Heat Exchanger for Citroën C5, C8 and Peugeot 607, 807 with 2.0 HDi or 2.2 HDi Engines.
This intake filter box with integrated water–air heat exchanger is a direct-fit solution for PSA 2.0 HDi and 2.2 HDi engines. Designed for professional workshops and DIY mechanics, the unit combines air filtration with a coolant-fed heat exchanger to stabilise intake-air temperature and reduce condensation in the intake tract. Commonly searched by OEM and reference numbers (9640454480, 964045780, 1427J3, 144200), this part restores proper air flow and prevents water ingress that can affect engine performance, turbo response and emissions control.
Technical Information
- Manufacturer: Stellantis / Citroën / Peugeot
- Model: Citroën C5, Citroën C8, Peugeot 607, Peugeot 807
- Product Codes: 9640454480, 964045780
- Additional Numbers: 1427J3, 144200
Function and Benefits
The unit houses the air filter element and an integrated water–air heat exchanger. By exchanging heat between engine coolant and the intake air, the exchanger helps to:
- Reduce condensation and water accumulation inside the intake tract.
- Stabilise intake-air temperature for improved cold-start behaviour and combustion consistency.
- Protect downstream components (turbocharger, MAF sensor, EGR) from excessive moisture and contamination.
Fitment and Compatibility
Direct fit for listed Citroën and Peugeot models equipped with 2.0 HDi or 2.2 HDi diesel engines. Always check the reference numbers (9640454480 / 964045780 / 1427J3 / 144200) against the vehicle’s parts catalog when confirming fitment. This item is intended for the intake system where the filter housing and coolant connection points match the OEM layout.
Installation Recommendations
Recommended for installation by experienced technicians or competent DIY mechanics with basic workshop tools. Typical replacement steps:
- Work on a cold engine. If the exchanger is connected to the cooling circuit, relieve system pressure and be prepared to capture any coolant that may spill.
- Disconnect intake hoses, clamps and any electrical connectors (MAF sensor, intake sensors) attached to the housing.
- Unfasten mounting screws/clips securing the filter box and remove the assembly carefully to avoid damage to the exchanger or attached hoses.
- Replace sealing gaskets and hose clamps as needed. Ensure all seals are seated correctly and fastening points are torqued to the manufacturer’s specification.
- After installation, refill and bleed the cooling circuit if it was opened. Start the engine and check for air intake leaks and coolant leaks around the exchanger connections.
Most Common Failure Causes
- Plastic fatigue and cracking from heat cycles and vibration, leading to air leaks or coolant seepage.
- Corrosion or internal blockage of the heat exchanger caused by contaminated or degraded coolant.
- Clogging from dirt, oil or soot in the intake path reducing airflow and performance.
- Damaged seals or hose connections allowing water or air leaks.
- Mechanical damage during removal or reinstallation (broken clips, stripped threads).
Service Advice
There is no fixed service interval for the filter box with heat exchanger; lifespan depends on operating conditions and maintenance. Inspect the unit during major services or when symptoms appear: reduced engine performance, unusual intake moisture, coolant loss, or visible cracks. Replace if leaking, heavily contaminated or mechanically damaged. Use genuine replacement parts or equivalent-quality components and renew seals and clamps during installation to ensure long-term reliability.
