Expansion Valve Refrigerant Lines, Disconnecting and Connecting
Expansion Valve Refrigerant Lines, Disconnecting and Connecting
Removing
- Discharge refrigerant circuit.
- Remove the components that hinder access to the mounting bolts for refrigerant lines - A - on expansion valve.
• Depending on engine and version of vehicle, it may be necessary to loosen or to remove the following components (top engine cover, pressurized air pipe to throttle valve part and depending on engine the intake manifold, etc.).
• Depending on the engine (for example, on certain 2.0L diesel engine, depending on the exhaust system version), it may be necessary to remove the plenum chamber cover and the plenum chamber front wall - A - in order to remove the head shield, and the refrigerant lines from the expansion valve and the coolant hoses to the heater core.
• The heat shield - B - is available in different versions. For version 1, sheet metal nuts - A - must be removed and heat shield - B - disengaged from vehicle.
• On version 2, clamping washers - A - and clamp - C - must be removed and heat shield - B - disengaged from vehicle. If heat shield - B - hinders further work because of the coolant hoses, separate heat shield - B - at locations marked with - D - (e.g. using a diagonal cutter) and remove it completely.
• For the sake of clarity, the illustrations show the heat shield - B - with the engine removed.
- If present, disengage heat shield - B - from front wall of plenum chamber front wall and from the bulkhead and set it aside (or remove it completely).
- Remove bolts - A - (tightening specification: 10 Nm).
- Disconnect refrigerant lines - B - and - C -.
• Seal open lines and the connections on the expansion valve with suitable caps (to prevent dirt and moisture from entering).
Installing
Installation is the reverse of removal, noting the following:
- Replace O-rings seals - D - and - E -. Refer to=> [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-Rings and Electronic Parts Catalog.
- Check fitted pin - G - (installed in connection or in expansion valve, not installed at all connections) and sleeve - H - for damage and proper seating.
• Coat the O-ring seals lightly with refrigerant oil prior to installation. Refer to=> [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-Rings.
• Check the O-rings for proper seating within the groove - F - on the refrigerant line.
• Install refrigerant pipes such that they are not strained.
• Depending on vehicle equipment and on engine, heat insulation has been applied to refrigerant lines, these must not be damaged and must be re-applied after installing.
• Check installation position of refrigerant lines to expansion valve (they must not contact other components) and position and state of heat protection insulation applied to refrigerant lines if necessary (not installed on all engine types).