Expansion Valve: Service and Repair

Evaporator Expansion Valve Replacement

1. Recover the refrigerant with a recovery/recycling/charging station A/C Refrigerant Recovery.

2. Remove the bolt from the A/C line clamp (A).






3. Remove the bolt, then disconnect the A/C line (A) from the evaporator core, and remove the O-rings (B).






4. Remove the blower unit Blower Unit Removal/Installation.

5. Disconnect the connectors (A) from the evaporator temperature sensor and the power transistor, then remove the connector clip (B). Remove the self-tapping screws, the expansion valve cover (C), and the seal (D).






6. Remove the self-tapping screw (A), push the upper cover (B) toward the front of the vehicle, then remove the upper cover.






7. Remove the bolts and the expansion valve (A) and the inlet/outlet lines from the evaporator core assembly without bending the lines.






8. Remove the inlet/outlet lines (A) from the expansion valve (B).






9. Install the expansion valve in the reverse order of removal, and note these items:

- Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage.
- Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption.
- Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately.
- Make sure that there is no air leakage.
- Charge the system A/C System Charging.