Expansion Valve: Service and Repair

FRONT

WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION.

REMOVAL
1. Disconnect and isolate the battery negative cable.
2. Recover the refrigerant from the refrigerant system.
3. Remove the rear liquid line from the engine compartment.
4. Remove the electronic cycling clutch switch from the outboard side of the expansion valve.

Expansion Valve Remove/Install:

5. Remove the two screws that secure the expansion valve to the evaporator tube mounting flange.
6. Remove the expansion valve from the evaporator tube mounting flange. install plugs in, or tape over all of the opened refrigerant line fittings.

INSTALLATION
1. Remove the tape or plugs from the evaporator tubes and the evaporator tube mounting flange side of the expansion valve. Install the expansion valve to the evaporator tube mounting flange and secure with two screws. Tighten the mounting screws to 11.4 Nm (100 in. lbs.).
2. Reinstall the electronic cycling clutch switch to the outboard side of the expansion valve.
3. Reinstall the rear liquid line to the engine compartment.
4. Connect the battery negative cable.
5. Evacuate the refrigerant system.
6. Charge the refrigerant system.

REAR

WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION.

REMOVAL

Rear Expansion Valve Removal/Install:

1. Disconnect and isolate the battery negative cable.
2. Recover the refrigerant from the refrigerant system.
3. Remove the engine air filter housing.
4. Remove the underbody line. Remove the line from the vehicle and install plugs in, or tape over, all of the open refrigerant fittings.
5. Disassemble the bolt (M6) from the forward (longer) section of the underbody lines to the valve. install plugs in, or tape over the open refrigerant fittings.
6. Disassemble the two bolts attaching the expansion valve to the rearward (shorter) section of the underbody lines. install plugs in, or tape over the open refrigerant fittings.

INSTALLATION
1. Remove the tape or plugs from expansion valve and the rearward (shorter) section of the underbody lines. Align the expansion valve ports with the block fitting on the rearward lines and assemble with the two bolts.
2. Remove the tape or plugs from the forward (longer) section of the underbody lines. Align the expansion valve ports and stud with the block fitting on the forward lines. Secure with the mounting bolt.
3. Install the underbody refrigerant lines.
4. Install the engine air filter housing.
5. Evacuate and charge the refrigerant system.
6. Connect the battery negative cable.