Expansion Block/Orifice Tube: Service and Repair
Air Conditioning Evaporator Thermal Expansion Valve Replacement
Removal Procedure
Warning: Refer to Safety Glasses Warning (Safety Glasses Warning).
1. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (Service and Repair).
2. Remove the engine cover. Refer to Engine Cover Replacement (Service and Repair) or Engine Cover Replacement (Service and Repair).
3. Recover the refrigerant Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).
4. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
5. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) or Air Cleaner Assembly Replacement (Service and Repair).
6. Disconnect the vacuum hose (1) and the vacuum brake booster check valve (3) from the vacuum brake booster (2).
7. Detach the vacuum hose (1) from the bulkhead mounted vacuum hose retaining bracket (4) and position aside.
8. Remove the remote battery positive post cover (1).
9. Remove the remote battery positive post to wiring harness retaining bolt (1).
10. Remove the starter motor power cable (2) and position aside.
11. Remove the suction pipe upper to suction pipe lower retaining nut (1).
12. Remove the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
13. Detach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).
14. Disconnect the suction pipe upper (1) from suction pipe lower (2).
Note: The sealing washer (3) is a single use item and must be discarded after use.
15. Remove the sealing washer (3). Refer to Sealing Washer Replacement (Sealing Washer Replacement).
Discard the sealing washer
Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.
16. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).
17. Remove the suction pipe/liquid pipe pad to TX valve retaining nut (1).
18. Disconnect the suction pipe/liquid pipe pad (3) from the TX valve (1).
Note: The sealing washers (2) are a single use item and must be discarded after use.
19. Remove the sealing washers (2). Refer to Sealing Washer Replacement (Sealing Washer Replacement).
Discard the sealing washers
Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.
20. Cap or plug the suction pipe (4) and liquid pipe (5).
Note: Using a suitable tool, unscrew the TX valve to evaporator pad retaining screws (1).
21. Remove the TX valve to evaporator pad retaining screws (1).
Note: If required, reinstall the suction pipe/liquid pipe to TX valve retaining nut to assist in the removal of the TX valve.
Note: Place the TX Valve in a plastic bag to avoid any contamination from air born dirt or moisture.
22. Remove the TX valve (3) from the evaporator pad (1).
Note: The sealing washers (2) are single use items and must be discarded after use.
23. Remove the sealing washers (2) from the evaporator pad (1). Refer to Sealing Washer Replacement (Sealing Washer Replacement).
Discard the sealing washers
Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.
24. Cap or plug the evaporator pad (1) and the TX valve (3).
Installation Procedure
1. Remove the plugs or caps from the thermal expansion (TX) valve (3) and the evaporator pad (1).
Note: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.
2. Install NEW sealing washers (2) to the evaporator pad (1). Refer to Sealing Washer Replacement (Sealing Washer Replacement).
3. Connect the TX valve (3) to the evaporator pad (1).
Caution: Refer to Fastener Caution (Fastener Caution).
4. Install TX valve to evaporator pad retaining screws (1) and tighten to4 Nm (35 lb in).
5. Remove the plugs or caps from the suction pipe (4), liquid pipe (5) and the TX valve (1).
Note: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.
6. Install NEW sealing washers (2). Refer to Sealing Washer Replacement (Sealing Washer Replacement).
7. Position the suction pipe/liquid pipe pad (3) to the TX Valve (1).
8. Install the suction pipe/liquid pipe pad to TX valve retaining nut (1) and tighten to 22 Nm(16 lb ft).
9. Remove the plugs or caps to the suction pipe upper (1) and the suction pipe lower (2).
Note: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.
10. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement (Sealing Washer Replacement).
11. Install the suction pipe upper (1) to the suction pipe lower (2).
12. Attach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).
13. Install the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
14. Install the suction pipe upper to suction pipe lower retaining nut (1) and tighten to 22 Nm( 16 lb ft).
15. Install the starter motor positive cable (2) to the remote battery positive post (3).
16. Install the remote battery positive post to wiring harness retaining bolt (1) and tighten to 15 Nm (11 lb ft).
Note: Make sure the clips on the remote battery positive post cover (1) are engaged to avoid an induced rattle condition.
17. Install the remote battery positive post cover (1).
18. Connect the vacuum hose (1) and the vacuum brake booster check valve (3) to the vacuum brake booster (2).
19. Attach the vacuum hose (1) to the bulkhead mounted vacuum hose retaining bracket (5).
20. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
21. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (Service and Repair).
22. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) or Air Cleaner Assembly Replacement (Service and Repair).
23. Install the engine cover. Refer to Engine Cover Replacement (Service and Repair) or Engine Cover Replacement (Service and Repair).
24. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
25. Leak test the thermal expansion valve pipe connections. Refer to Leak Testing (Leak Testing).