Expansion Valve: Service and Repair

1. Disconnect the battery negative terminal.
2. Use a Refrigerant Recovery/Recycling System to recover the refrigerant from the system.





3. Disconnect the receiver line and suction hose from the evaporator.

CAUTION: Cap the open fittings immediately to keep moisture and dirt out of the system.

4. Remove the tapping screws (4) and glove box lower cover.
5. Remove the screws (2) and glove box.
6. Remove the screws (4), bolt (1) and glove box frame.
7. Disconnect the drain hose from the evaporator lower housing.
8. Loosen the sealing band and slide it toward the blower.





9. Disconnect the thermostat wire, and pull the wire out of the clamp at the top of the evaporator.
10. Remove the evaporator by removing the three bolts and two tapping screws.
11. Remove the sealing band from the blower if necessary.





12. Remove the self-tapping screw and clip from the housing.
13. Carefully separate the housings as required to obtain access to the capillary tube in the housing.
14. Pull out the capillary tube of the thermostat from the evaporator fins.
15. Separate the housings and remove the evaporator cover.
16. Remove the expansion valve.
17. Assemble the evaporator in the reverse order of disassembly, noting the following:
- Torque expansion valve fittings to specifications:
Expansion valve to evaporator core: 34 Nm (25 lb ft)
Expansion valve to receiver line: 18 Nm (13 lb ft)
- Install the expansion cover capillary tube against the suction line, and wrap it with tape.
- Reinstall the thermostat capillary tube in its original location.
- Reassemble the upper and lower housings with clips, make sure there are no gaps between them.
18. Install the evaporator in the reverse order of removal.
19. Charge the system and test performance.