Expansion Valve: Service and Repair

WARNING:
- AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE.

- R-134a SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR/R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE.

REMOVAL
1. Remove refrigerant from the A/C system using a refrigerant recovery machine.

Liquid Line Clip:

Suction Line Clip:

2. Disconnect clips from expansion valve lines.

Special Tool 7240 For Liquid Line:

Special Tool 7242 For Suction Line:

3. Use special tool kit 7193 to disconnect quick connectors on expansion valve.

Lines At Expansion Valve:

4. Remove lines at expansion valve.

Expansion Valve Bolts:

5. Remove two retaining bolts from expansion valve.

Expansion Valve:

6. Remove expansion valve.
7. Remove expansion valve gasket.

INSTALLATION

CAUTION: Always install a new gasket when replacing expansion valve.

For installation, reverse the above procedures. Tighten new expansion valve to 11 Nm (100 in. lbs.).