Expansion Valve: Service and Repair

REMOVAL

WARNING: REVIEW THE WARNINGS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.

1. Recover the refrigerant from the system.
2. Remove the engine air inlet tube and the air distribution duct on vehicles equipped with 3.2/3.5 L engine.
3. Remove one nut to the a/c lines at the expansion valve.
4. Loosen the bolt at the receiver/drier to pivot the lines away from the expansion valve.
5. Plug or cap the open end of the refrigerant lines.
6. Gently pull the a/c line out of the expansion valve.
7. Remove two #30 torx bolts retaining the expansion valve to the a/c evaporator.
8. Remove the expansion valve from the vehicle.

CAUTION: Always install new O-rings when replacing the a/c expansion valve.

INSTALLATION

WARNING: REVIEW THE WARNINGS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.

Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.

High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.

1. Install the a/c expansion valve on the a/c evaporator. Tighten the fasteners to 23 Nm (17 ft. lbs.).
2. Connect the lines to the expansion valve and tighten the retaining nut to 23 Nm (17 ft. lbs.).
3. Tighten the bolt at the receiver/drier to 13.6 Nm (10 ft. lbs.).
4. Install the engine air inlet tube and the air distribution duct on vehicles equipped with 3.2/3.5 L engine.
5. Evacuate the refrigerant system.
6. Charge the refrigerant system.