Expansion Valve: Service and Repair

REMOVAL

WARNING:
- AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE.
- R-134a SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR/R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE.

1. Remove refrigerant from the A/C system using a refrigerant recovery machine.
2. Remove ground wire from the expansion valve.

Fig.10 Suction And Liquid Lines At Expansion Valve:

3. Remove bolt attaching suction and liquid lines to expansion valve.

Fig.11 Expansion Valve Bolts:

4. Remove two retaining bolts from expansion valve.

Fig.12 Expansion Valve:

5. Remove expansion valve.
6. Remove expansion valve gasket.

INSTALLATION

CAUTION: Always install a new gasket when replacing expansion valve.

1. Position a new gasket and the expansion valve on the evaporator.
2. Install the expansion valve retaining bolts. Tighten to 11 Nm (100 in. lbs.).
3. Position the suction and discharge lines and a new seal on the expansion valve.
4. Install the refrigerant line retaining bolt to the expansion valve.
5. Install the ground wire and screw to the expansion valve.
6. Evacuate the refrigerant system.
7. Recharge the refrigerant system.