Operation CHARM: Car repair manuals for everyone.
Home >> Dodge and Ram >> 1999 >> Durango 4WD V8-5.9L VIN Z LDC >> Repair and Diagnosis >> Heating and Air Conditioning >> Technical Service Bulletins >> All Technical Service Bulletins >> Rear A/C Unit - Blows Warm Air When Hot Outside >> Repair Procedure >> Expansion Thermal Valve

Expansion Thermal Valve

1. Follow the Refrigerant Recovery procedures identified in the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-28 and 24-29 and evacuate the A/C system.

NOTE:
IT IS EXTREMELY IMPORTANT THAT YOU RECLAIM AND WEIGH ANY REFRIGERANT OIL FROM THE REFRIGERANT AFTER IT IS RECOVERED FROM THE A/C SYSTEM.

2. Remove the liquid refrigerant line that is routed between the filter/drier and the front expansion valve. Refer to the 1999 Durango Service Manual (Publication No.81-370-9116), page 24-38 for information regarding Liquid Line - Rear removal procedures.

NOTE:
ALL REFRIGERANT OIL THAT IS DRAINED FROM THE LIQUID REFRIGERANT LINE MUST BE MEASURED TO ENSURE THAT THE APPROPRIATE AMOUNT OF OIL IS ADDED TO THE SYSTEM AFTER ALL COMPONENTS HAVE BEEN ASSEMBLED.





3. Unplug the wire harness connector from the electronic cycling clutch switch near the expansion valve (Figure 3).

4. Remove and discard the fastener that secures the electronic cycling switch to the outboard side of the expansion valve.

5. Pull the electronic cycling clutch switch away from the expansion valve far enough for the thermistor probe capillary tube to clear the well in the expansion valve. The washer bottle may have to be removed.

NOTE:
THE CAPILLARY TUBE WELL IN THE EXPANSION VALVE IS FILLED WITH SPECIAL THERMALLY-CONDUCTIVE GREASE. THIS GREASE SHOULD BE REMOVED FROM THE EXPANSION VALVE AND REUSED ON THE NEW EXPANSION VALVE P/N 55055773AF.





6. Remove the two screws that secure the expansion valve to the evaporator tube mounting flange (Figure 4).

7. Remove the expansion valve from the evaporator tube mounting flange.

NOTE:
THE EVAPORATOR TUBE MOUNTING FLANGE SHOULD BE PLUGGED UNTIL THE NEW EXPANSION VALVE IS READY TO BE INSTALLED.

8. Remove the caps, then install the new expansion valve p/n 55055773AF onto the evaporator tube mounting flange and secure with two screws. Tighten the mounting screws to 11.4 N.m (100 in. lbs.).

9. Ensure that the capillary tube well is filled with the thermally-conductive grease removed earlier then, insert the thermistor probe capillary tube of the electronic cycling clutch switch into the well.

10. Install the electronic cycling clutch switch onto the expansion valve and secure it with a new fastener p/n 05015797AA.

11. Plug the wire harness connector into the electronic cycling clutch switch.

12. Remove the underbody refrigerant line. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 24-43 for information regarding Underbody Refrigerant Line removal procedures.

NOTE:
ALL REFRIGERANT OIL THAT IS DRAINED FROM THE UNDERBODY REFRIGERANT LINE OR THE LINES GOING TO THE REAR OVERHEAD A/C EVAPORATOR MUST BE MEASURED TO ENSURE THAT THE APPROPRIATE AMOUNT OF OIL IS ADDED TO THE SYSTEM AFTER ALL COMPONENTS HAVE BEEN ASSEMBLED.





13. Disassemble the bolt from the forward section of the underbody refrigerant line assembly to the expansion valve (Figure 5). Install plugs in or tape over the open refrigerant fittings.

14. Disassemble the two bolts attaching the expansion valve to the rearward (shorter) section of the underbody refrigerant lines.

NOTE:
THE REARWARD SECTION OF THE UNDERBODY REFRIGERANT LINES SHOULD BE PLUGGED UNTIL THE NEW EXPANSION VALVE IS READY TO BE INSTALLED.

15. Remove the caps, then install the new expansion valve p/n 55055876AB onto the rearward section of the underbody refrigerant line mounting flange and secure with two screws. Tighten the mounting screws to 11.4 N.m (100 in. lbs.).

16. Remove the tape or plugs from the forward section of the underbody refrigerant lines. Install new O-rings onto the mounting flange then, align the expansion valve ports and stud with the block fitting on the forward section of the underbody refrigerant lines. secure the lines with the mounting bolt.

17. Install the underbody refrigerant lines. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 24-44 for information regarding Underbody Refrigerant Line installation procedures.

18. Install the liquid refrigerant line that is routed between the filter/drier and the front expansion valve. Refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), page 24-39 for information regarding Liquid Line - Rear installation procedures.

19. Follow the Refrigerant Recovery procedures identified in the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-28 and 24-29 and evacuate the A/C system.

20. Weigh all compressor oil that was reclaimed from the A/C refrigerant and/or drained from the A/C components during this repair procedure. Add this amount of new refrigerant oil (SP-20 PAG oil) p/n 04886129AA to the A/C system.

NOTE:
IF THE RECYCLING STATION IS NOT EQUIPPED WITH A DEVICE TO ADD OIL TO AN EVACUATED SYSTEM, OIL COULD BE ADDED TO THE A/C SYSTEM BY REMOVING THE SUCTION AND DISCHARGE LINES AT THE COMPRESSOR AND INSTALLING THE OIL DIRECTLY INTO THE COMPRESSOR.

21. After the A/C system has been evacuated and tested for leaks, add 32 oz. of R134a refrigerant to the A/C system. A R134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the A/C system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment.

22. Clean all dirt and debris from the A/C underhood label then, install new label p/n 55055728AD over the existing label.

23. Verify proper operation of the A/C system. If necessary, refer to the 1999 Durango Service Manual (Publication No. 81-370-9116), pages 24-13 through 24-16 for information regarding front A/C performance testing and Technical Service Bulletin 24-16-98 for rear A/C performance testing.
pro multis · About Operation CHARM