Expansion Valve: Service and Repair

Thermostatic Expansion Valve

Service Repair No - 82.25.01

Removal

All vehicles
1. Disconnect the battery ground cable.
2. Remove the plenum chamber.
3. Recover the air conditioning (A/C) refrigerant.

All vehicles

CAUTION: Make sure that all openings are sealed.Use new blanking caps.

4. Disconnect the A/C pipes.
^ Remove the 2 bolts.
^ Remove and discard the 2 O-ring seals.





NOTE: LH illustration shown, RH is similar.

5. Remove the floor console extension trim panel.
^ Remove the screw.
^ Release the 2 clips.





Right-hand drive vehicles

6. Release the driver side closing trim panel.
^ Remove the 4 screws.
^ Remove the clip.





7. Remove the driver side closing trim panel.
^ Disconnect the 2 electrical connectors.
^ Release the vehicle diagnostic socket.





8. Remove the right-hand front footwell duct.
^ Remove the 2 screws.

Left-hand drive vehicles

9. Remove the passenger side closing trim panel.
^ Remove the 3 screws.
^ Remove the electrical connector.





10. Remove the passenger side footwell duct.
^ Remove the screw.





All vehicles

11. Remove the thermostatic expansion valve cover.
^ Release the wiring harness from the 2 tangs.
^ Remove the 4 screws.





CAUTION: Make sure that all openings are sealed.Use new blanking caps.

12. Remove the thermostatic expansion valve.
^ Remove the 2 bolts.
^ Remove the 2 A/C pipe clamps.
^ Remove the A/C pipes.
^ Remove and discard the O-rings.





Installation

All vehicles

1. Install the thermostatic expansion valve.
^ Remove the blanking caps from the ports.
^ Clean the component mating faces.
^ Lubricate and install the new O-rings.
^ Install the A/C pipes.
^ Install the 2 A/C pipe clamps.
^ Tighten the bolts to 6 Nm (4 ft. lbs.).
2. Install the thermostatic expansion valve cover.
^ Install the 4 screws.
^ Secure the wiring harness to the tangs.

Right-hand drive vehicles

3. Install the right-hand front footwell duct.
^ Install the screws.
4. Install the driver side closing trim panel.
^ Connect the electrical connectors.
^ Attach the vehicle diagnostic socket.
5. Secure the driver side closing trim panel.
^ Install the screws.
^ Install the clip.

Left-hand drive vehicles

6. Install the passenger side closing trim panel.
^ Connect the electrical connector.
^ Install the screws.
7. Install the passenger side footwell duct.
^ Install the screw.

NOTE: LH illustration shown, RH is similar.

8. Install the floor console extension trim panel.
^ Secure the clips.
^ Install the screw.
9. Connect the A/C pipes.
^ Remove the blanking caps from the ports.
^ Clean the component mating faces.
^ Lubricate and install the new O-rings.
^ Install the A/C pipes.
^ Tighten the bolts to 6 Nm (4 ft. lbs.).
10. Recharge the A/C system.
11. Install the plenum chamber.
12. Disconnect the battery ground cable.