Expansion Valve: Service and Repair

REMOVE
WARNING: On vehicles equipped with rear A/C, the refrigerant system must be emptied before performing the following operation. The engine cooling system must also be relieved of all pressure.

Rear Heater Plumbing:

1. Drain engine cooling system. Disconnect heater hoses at rear heater A/C unit.

Rear A/C Plumbing:

2. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C plumbing from rear heater A/C unit.
3. Remove left lower quarter trim panel.
4. Remove screws securing air distribution duct to the rear wheel housing.
5. Remove screws securing heater unit to the floor pan.
6. Remove screw securing unit to the quarter panel support.
7. Lift the unit enough to clear floor pan. Remove unit from the vehicle.

EVAPORATOR AND EXPANSION VALVE
1. Remove unit cover.
2. Remove the bolt that mounts the unified refrigerant plumbing block to the expansion valve.
3. Carefully pull the evaporator and expansion valve straight out of unit.

CAUTION: Do not scratch the sealing surfaces with the plumbing extension tube pilots.

4. Remove and discard the aluminum gasket between the plumbing extension and the expansion valve.
5. Cover the plumbing extension sealing surface to prevent contamination.
6. Bring evaporator and expansion valve to a clean work space.
7. Remove two 1/4-20 Torx Head screws.
8. Remove expansion valve.
9. Measure and record the amount of residual oil from the removed evaporator.

INSTALL
1. Replace the aluminum gaskets.
2. Hold expansion valve against evaporator sealing plate

CAUTION: Do not scratch the sealing surface.

3. Install two screws and tighten to 70 to 130 inch pounds (8 to 14 Nm).
4. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots.
5. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of clean refrigerant oil) back into the system.
6. Carefully align the expansion valve onto the pilot tube of the plumbing sealing plate (do not scratch the sealing surface). Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolts to 170 to 230 inch pounds (20 to 26 Nm).
7. Install unit cover and air distribution duct.
8. Install quafter trim panel, evacuate/charge system, and test performance.