Expansion Valve: Service and Repair

REMOVAL

WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION.

1. Recover the refrigerant from the refrigerant system.
2. Disconnect and isolate the negative battery cable.

A/C Expansion Valve - 2.4L Shown, RHD Typical:

3. Disconnect the wire harness connector from the A/C low pressure switch.
4. Remove the bolt that secures the suction and liquid line fitting to the A/C expansion valve.
5. Disconnect the suction line and liquid line fittings from the A/C expansion valve and position the refrigerant lines out of the way.
6. Remove the gasket from the A/C expansion valve and discard.
7. Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports.
8. Remove the two bolts that secure the A/C expansion valve to the evaporator tube tapping plate.
9. Remove the A/C expansion valve from the evaporator tube tapping plate.
10. Remove the gasket from the evaporator tube tapping plate and discard.
11. Install plugs in, or tape over the opened evaporator inlet and outlet tube fittings and both expansion valve ports.
12. If required, remove the A/C low pressure switch from the A/C expansion valve.

INSTALLATION
1. If removed, install the A/C low pressure switch to the A/C expansion valve. Tighten the switch securely.
2. Remove the tape or plugs from the evaporator inlet and outlet tube fittings and both ports on the back of the A/C expansion valve.
3. Install a new gasket onto the evaporator tube tapping plate
4. Position the A/C expansion valve onto the evaporator tube tapping plate.
5. Install the two bolts that secure the A/C expansion valve to the evaporator tube tapping plate plate. Tighten the bolts to 10 Nm (88 in. lbs.).
6. Remove the tape or plugs from the liquid and suction line fittings and both ports on the front of the A/C expansion valve.
7. Install a new gasket onto the A/C expansion valve.
8. Connect the liquid and suction line fitting to the A/C expansion valve.
9. Install the bolt that secures the suction and liquid line fitting to the A/C expansion valve. Tighten the bolt to 20 Nm (15 ft. lbs.).
10. Connect the wire harness connector to the A/C low pressure switch.
11. Reconnect the negative battery cable.
12. Evacuate the refrigerant system .
13. Recharge the refrigerant system .