Expansion Valve: Service and Repair

Removal

1. Take off battery ground cable.

2. Draw off refrigerant with service equipment.





3. Remove carpet liner from the trunk.





4. Remove fuel tank. Image above depicts fuel tank hose connections.













5. Remove fuse block and 5 firewall bolts. Images above depict removal of these items.




Note: Airbox components are shown in the image above.

6. Remove the pollen filter covers and the filters themselves. The covers are two thumb screws and the filters are keyed so that the tabs face upwards upon removal.

7. Remove the Air intake grill and retainer frame shown in the image above. Inside the grill, there are 2 bolts that hold the airbox intake that need to be removed.






13. Disconnect A/C lines to the expansion valve (shown in the image above). Swing the 2 A/C lines out of the way.





17. Undo and take out expansion valve. Plug piping to evaporator immediately with airtight seals.

Installation
Remove plugs only directly before refitting. Replace O-rings and coat lightly with refrigerant oil.

Refrigerant oil drawn off from an A/C system that has already been operated must not be reused.

Tightening torques:
M 5 bolt 6 Nm (4.5)
M 6 bolt 9 Nm (6.6)

1. Recharge A/C system refrigerant.

2. Reverse removal procedure.