Expansion Valve: Service and Repair

EVAPORATOR UNIT REMOVAL





CAUTION:
- All SRS electrical wiring harnesses are covered with yellow outer insulation.
- Before disconnecting the SRS wire harness, install the short connector(s) on the airbag(s).
- Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring.

1. Disconnect the negative cable from the battery.
2. Use a Refrigerant Recovery/Recycling System to recover the refrigerant from the system.





3. Disconnect the receiver line and suction line from the evaporator.

CAUTION: Cap the open fittings immediately to keep moisture out of the system.





4. Remove the glove box and the glove box frame.





5. Remove the two self-tapping screws and A/C bands.





6. Disconnect the connector from the A/C thermostat.
7. Remove the nuts and drain hose, then remove the evaporator.

EXPANSION VALVE REPLACEMENT





1. Pull out the A/C thermostat sensor from the evaporator fins.
2. Remove the self-tapping screws and clips from the housing.
3. Carefully separate and remove the upper and lower housings.
4. Remove the expansion valve.
5. Assemble the evaporator in the reverse order of disassembly, and:
- Apply a thin coat of refrigerant oil to the new 0-rings at joint nuts.
- Install the expansion valve capillary tube so it contacts the suction line, and wrap it with tape.
- Reinstall the A/C thermostat sensor in its original location.

EVAPORATOR UNIT INSTALLATION
- Install in the reverse order of removal, and:
- Add refrigerant oil.
- Replace 0-rings with new ones at the pipe joints, and apply a thin coat of refrigerant oil before installing them.
- Apply a sealant to the grommets.
- Make sure that there is no air leakage.
- Charge the system and test the performance.