Expansion Valve: Service and Repair

Expansion Valve

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331) (5 to 50 Nm)

• Robinair A/C Service Unit (ROB 134APF) or succeeding model.

• Drip Tray For Shop Crane (VAS 6208)

• Refrigerant must be extracted before hand using e.g. (ROB 134APF).

• The previously used service stations can still be used. Refer V.A.G workshop equipment catalog.

• To prevent the entry of dampness all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.

• On some vehicles, connecting pipe from charge air cooler should be removed.

Only for vehicles with a heat shield in front of the expansion valve

- Remove the nuts - 1 - (9 +/-1.3 Nm).






- Remove the heat shield- 2 -.

- Place (VAS 6208) under the engine.


Contact with hot engine coolant can cause severe scalding.

Coolant temperature can be above 100 °C (212° F) with a warm engine. The cooling system is under pressure.

If necessary, reduce pressure and temperature before repairs.

- Disconnect the heater core coolant pipe- 2 -.






- Remove the nut - 1 - (9 +/- 1.3 Nm) and bolt - 3 - (9 +/-1.3 Nm).

- Lightly pull the coolant pipe in the direction of the engine.

All vehicles






1 Screws

• 10 +/- 1 Nm

• Quantity: 2

2 Refrigerant Lines On Expansion Valve

3 O-ring

• 13.7 mm; 2.5 mm

4 Expansion Valve

• Removing:

- Extract refrigerant using (ROB 134APF).


There is a danger of ice-up.

Refrigerant leaks out if refrigerant circuit is not discharged.

Refrigerant must be extracted before opening the refrigerant circuit. If refrigerant circuit is not opened within 10 minutes of extraction, pressure may form in refrigerant circuit due to evaporation. Extract refrigerant once more.

- Remove the bolts - 1 - and the refrigerant pipes - 2 - from the expansion valve.

- Remove the bolts - 8 - and the expansion valve - 4 -.

5 O-ring

• 14 mm; 1.82 mm

• Coat with refrigerant oil when installing

6 O-ring

• 10.8 mm; 1.82 mm

• Coat with refrigerant oil when installing

7 O-ring

• 9.5 mm; 2.5 mm

8 Cylindrical Combination Bolt

• 5 Nm