Expansion Valve Replacement

1. Disconnect the positive and negative battery terminals.





2. Connect the A/C Charging/Recovery Station to the high and low pressure A/C taps on the vehicle and recover the refrigerant.





3. From the driver's side of the vehicle, disconnect the mode control cable from the cable housing retaining clip and from the mode control bellcrank.





4. From the passenger side of the vehicle disconnect the temperature control cable from the cable housing retaining clip and from the temperature control bellcrank.





5. M/T ONLY: Remove the shift lever knob by unscrewing the knob from the shift lever.

6. A/T ONLY: Disengage the transaxle shift interlock system and shift the transaxle into "D" (Drive).





7. Remove the four screws (two on each side) attaching the center console to the instrument panel.





8. Open the storage box and remove the two bolts from the center console.

NOTICE
The two bolts are located underneath the felt cushion.





9. Remove the ashtray and remove the one screw from the ashtray cavity.





10. Remove the facia around the shift lever to access the remaining center console attachment screw.

NOTICE
Disconnect the cigarette lighter electrical connector located at the back of the cigarette lighter before removing the facia.





11. Remove the one center console attachment screw.

12. Carefully lift and remove the center console from the vehicle.





13. Remove the four instrument panel lower center mounting bolts (two on each side).





14. Remove the three screws from the lower instrument panel cover and remove the cover.

15. Remove the three steering column cover screws then unsnap the lower cover from the upper cover.





16. Remove the two steering column bolts. Slide the driver's seat rearward and lower the steering column until the steering wheel contacts the floorboard.





17. Remove the instrument panel side covers (one on each side).





18. Remove the four instrument panel side mounting bolts (two on each side).





19. Pull the instrument panel away from the bulkhead to allow enough clearance for the blower motor assembly to be removed in steps 24 and 25.

20. Disconnect all blower motor electrical connectors.

CAUTION
DO NOT DISCONNECT THE AIRBAG SYSTEM ELECTRICAL CONNECTOR (YELLOW WIRE LOOM).





21. CRUISE CONTROL EQUIPPED VEHICLES ONLY: Remove the one nut and two bolts holding the cruise control actuator in place and move unit to the side.





22. Remove the two nuts securing the evaporator inlet and outlet pipes to the evaporator at the bulkhead in the engine compartment, then separate the block fitting from the evaporator.

23. Remove the two screws holding the locating plate to bulkhead and remove the plate.





24. Remove the five nuts securing the blower motor assembly to the bulkhead.

NOTICE
There are three nuts located below the blower motor assembly not shown in the photo.





25. Carefully remove the blower motor assembly from the vehicle and place on in a suitable work area.





26. Using a razor blade, carefully cut the foam gasket at the blower motor housing seam (two places), as shown in the photo.

NOTICE
Cutting the foam gasket is necessary to separate the two halves of the blower housing to gain access to the expansion valve.





27. Remove the five screws and four clips securing the two halves of the blower housing together, then separate the two halves of the blower housing to gain access to the expansion valve.





28. Remove the two allen head bolts securing the expansion valve to the evaporator tubes, then remove the expansion valve.

29. Install the new expansion valve.

NOTICE
Carefully inspect all four 0-rings before installing the new expansion valve. Make sure that there is no damage or cracks and that the 0-rings are positioned correctly on the pipes. Each 0-ring should be lubricated with refrigerant PAG Oil before installation.





30. Re-assemble the vehicle in reverse order of disassembly.

31. Evacuate and recharge the A/C system with 1.6 lbs of 134a refrigerant.

NOTICE
The air conditioner system must have a minimum of 15 minutes evacuation time. Additional evacuation time may be required depending on current climate conditions.