EXPANSION VALVE REMOVAL

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L.H.D.

1.  Disconnect the negative battery cable.

2.  Collect the refrigerant. (See REFRIGERANT CHARGING.)

3.  Remove the air cleaner installation bolt and slide the air cleaner component aside.

4.  Remove the cooler hose (LO) installation nut, and then remove the cooler hose (LO) bracket from the vehicle stud bolt.

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Caution

•  If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other malfunction could occur. Always plug open fittings immediately after removing any refrigeration cycle parts.

5.  Using the SSTs (49 B061 014, 49 G061 001) disconnect the cooler pipe and cooler hose from the A/C unit while not allowing the remaining compressor oil in the A/C compressor and pipes to spill. (See REFRIGERANT LINE REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].) (See REFRIGERANT LINE REMOVAL/INSTALLATION [MZ-CD 1.6].)

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6.  Remove the following parts:

(1)  Glove compartment (See GLOVE COMPARTMENT REMOVAL/INSTALLATION.)

(2)  Heat duct (RH) (See HEAT DUCT COMPONENT REMOVAL/INSTALLATION.)

(3)  Side wall (RH) (See SIDE WALL REMOVAL/INSTALLATION.)

7.  Disconnect the evaporator temperature sensor connector.

8.  Remove the evaporator temperature sensor wiring harness clip.

9.  Disconnect the power MOS FET connector. (full-auto air conditioner)

10.  Disconnect the resistor connector. (manual air conditioner)

11.  Make a hole in the position shown in the figure for the adhesive polyurethane (2) and remove the outlet pipe installation bolt.

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12.  Cut the adhesive polyurethane (2) near the contact surfaces of the expansion valve and outlet pipe, and tear it off.

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13.  Slide the outlet pipe to the right while being careful not to allow remaining compressor oil in the outlet pipe and expansion valve to spill.

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14.  Remove the expansion valve installation bolts.

15.  Remove the expansion valve while being careful not to allow the remaining compressor oil in the expansion valve and evaporator to spill.

16.  Tear off the adhesive polyurethane (2) from the expansion valve.

Caution

•  Because of the possibility of condensation forming, whenever possible remove the adhesive polyurethane carefully so that it does not damage the adhesive sponge rubber on the outlet pipe.

17.  Cut the adhesive polyurethane (2) as shown in the figure and remove the adhesive polyurethane (2) from the outlet pipe near the expansion valve.

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R.H.D.

1.  Disconnect the negative battery cable.

2.  Collect the refrigerant. (See REFRIGERANT CHARGING.)

3.  Remove the air cleaner installation bolt and slide the air cleaner component aside.

4.  Remove the cooler hose (LO) installation nut, and then remove the cooler hose (LO) bracket from the vehicle stud bolt.

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Caution

•  If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other malfunction could occur. Always plug open fittings immediately after removing any refrigeration cycle parts.

5.  Using the SSTs (49 B061 014, 49 G061 001) disconnect the cooler pipe and cooler hose from the A/C unit while not allowing the remaining compressor oil in the A/C compressor and pipes to spill. (See REFRIGERANT LINE REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].) (See REFRIGERANT LINE REMOVAL/INSTALLATION [MZ-CD 1.6].)

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6.  Remove the following parts:

(1)  Shift lever know (MTX) (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [F35M-R].) (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [B65M-R].)

(2)  Boot panel (See FRONT CONSOLE COMPONENT DISASSEMBLY/ASSEMBLY.)

(3)  Side wall (See SIDE WALL REMOVAL/INSTALLATION.)

(4)  Front console (See FRONT CONSOLE COMPONENT REMOVAL/INSTALLATION.)

(5)  Front scuff plate (RH) (See FRONT SCUFF PLATE REMOVAL/INSTALLATION.)

(6)  Front side trim (RH) (See FRONT SIDE TRIM REMOVAL/INSTALLATION.)

(7)  Bonnet release lever (See BONNET LATCH AND RELEASE LEVER REMOVAL/INSTALLATION.)

(8)  Driver's side lower panel (See LOWER PANEL REMOVAL/INSTALLATION.)

(9)  Steering shaft lower side L-shaped bracket (MTX) (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [R.H.D.].)

(10)  Heat duct (RH) (See HEAT DUCT COMPONENT REMOVAL/INSTALLATION.)

7.  Remove the clutch pedal installation nut and slide the clutch pedal upward. (MTX) (See CLUTCH PEDAL REMOVAL/INSTALLATION [F35M-R].) (See CLUTCH PEDAL REMOVAL/INSTALLATION [B65M-R].)

8.  Remove the air mix actuator. (full-auto air conditioner) (See AIR MIX ACTUATOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].)

9.  Put a hole in the adhesive polyurethane (2) in the position shown in the figure and remove the outlet pipe installation bolt.

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10.  Cut the adhesive polyurethane (2) near the contact surfaces of the expansion valve and outlet pipe, and tear it off.

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11.  Slide the outlet pipe to the right while being careful not to allow remaining compressor oil in the outlet pipe and expansion valve to spill.

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12.  Remove the expansion valve installation bolts.

13.  Remove the expansion valve while being careful not to allow the remaining compressor oil in the expansion valve and evaporator to spill.

14.  Tear off the adhesive polyurethane (2) from the expansion valve.

Caution

•  Because of the possibility of condensation forming, whenever possible remove the adhesive polyurethane carefully so that it does not damage the adhesive sponge rubber on the outlet pipe.

15.  Cut the adhesive polyurethane (2) as shown in the figure and remove the adhesive polyurethane (2) from the outlet pipe near the expansion valve.

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