Evaporator Core and Expansion Valve Replacement

NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor.

REMOVAL

WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE.


1. Remove right quarter trim panel and D-pillar trim.
2. Remove fan A/C distribution duct.
3. Remove rear A/C unit.
4. Remove blower scroll.

Evaporator Cover:

5. Remove evaporator cover.

Expansion Valve:

6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve.

Evaporator Removal:

7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots.
8. Remove and discard the O-rings between the plumbing extension and the expansion valve.
9. Cover the plumbing extension sealing surface to prevent contamination.
10. Bring evaporator and expansion valve to a clean work space.
11. Remove two 1/4-20 Torx Head screws.
12. Remove expansion valve.
13. Measure and record the amount of residual oil from the removed evaporator.

INSTALLATION
1. Replace the O-rings.
2. Hold expansion valve against evaporator sealing plate (do not scratch the sealing surface). Install two screws and tighten to 11 +/- 3 N.m (100 +/- 30 inch pounds) torque.

CAUTION: Do not damage the evaporator insulation liner during installation.

3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots.
4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of clean refrigerant oil) back into the system.
5. Carefully align the expansion valve onto the pilot tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolts to 23 +/- 3 N.m (200 +/- 30 inch pounds) torque.
6. Install evaporator cover and blower scroll.
7. Install quarter trim panel, evacuate/charge system, and perform the performance test.