Expansion Valve: Service and Repair

Remove or Disconnect
1. Evaporator and blower module from vehicle.
2. Clamps and heater inlet/outlet hoses from heater core pipes.
3. Retaining screw and heater core outlet pipe clamp (1135).
4. Retaining screw and heater core inlet pipe clamp (1152).
5. Retaining screws and heater outlet case (1131) from evaporator and blower module.
6. Retaining screw and heater core clamp (1134).
7. Retaining screws and heater core clip (1129).
8. Heater core (1128) from evaporator and blower module (1115).
9. Retaining screws and drain case (1139) from evaporator and blower module (1115).
10. Screws attaching heater and A/C evaporator blower cover case (1140) to heater and A/C evaporator case (1121).
11. Rear compartment outlet (beltline-horizontal) duct seal from top of two case halves (1121/1140).
12. Separate heater and A/C evaporator blower cover case (1140) from heater and A/C evaporator case (1121).
13. Evaporator core inlet tube fining from thermal expansion valve (1144). Use a backup wrench while loosening fitting.
14. Thermal expansion valve capillary tube retaining clip from evaporator core outlet tube.
15. Thermal expansion valve inlet tube (1150) fitting from thermal expansion valve. Use a backup wrench while loosening fitting (1144).
16. Thermal expansion valve inlet tube clamp (1151) from thermal expansion valve inlet tube (1150).

Install or Connect
1. Evaporator core inlet tube fitting to thermal expansion valve (1144).

Tighten:
^ Fitting to 37 Nm (27 lb. ft.). Use a backup wrench while torquing fitting.

2. Thermal expansion valve inlet tube (1150) fitting to thermal expansion valve (1144).

Tighten:
^ Fitting to 20 Nm (15 lb. ft.). Use a backup wrench while torquing fitting.

3. Thermal expansion valve inlet tube clamp (1151) to heater and A/C evaporator case (1121) with retaining screw.

Tighten:
^ Thermal expansion valve inlet tube clamp retaining screw to 3 Nm (27 lb. in.).

4. Thermal expansion valve capillary tube to evaporator core outlet tube with retaining clip. Make certain that capillary tube is attached to the horizontal mid-point of the evaporator core outlet tube.
5. Heater and A/C evaporator blower cover case (1140) to heater and A/C evaporator case (1121) with attaching screws.

Tighten:
^ Screws to 3 Nm (27 lb. in.).

6. Rear compartment outlet (beltline-horizontal) duct seal to top of two case halves (1121/1140).
7. Drain case (1139) to evaporator and blower module (1115) with retaining screws.

Tighten:
^ Drain case retaining screws to 3 Nm (27 lb. in.).

8. Heater core (1128) into evaporator and blower module (1115).
9. Heater core clamp (1134) with retaining screw.

Tighten
^ Heater core clamp retaining screw to 3 Nm (27 lb. in.).

10. Heater core clip (1129) with retaining screws.

Tighten:
^ Heater core clip retaining screws to 3 Nm (27 lb. in.).

11. Heater outlet case (1131) to evaporator and blower module (1115) with retaining screws.

Tighten:
^ Heater outlet case retaining screws to 3 Nm (27 lb. in.).

12. Heater core outlet pipe clamp (1135) with retaining screw.
13. Heater core inlet pipe clamp (1152) with retaining screw.

Tighten:
^ Heater core clamp retaining screws to 3 Nm (27 lb. in.).

14. Clamps and heater inlet/outlet hoses to heater core pipes.
15. Evaporator and blower module (1115) to vehicle.