Expansion Valve: Service and Repair

Underdash HVAC Component Layout:

1. Disconnect battery ground cable and discharge system refrigerant.
2. Disconnect refrigerant lines from cooling unit, capping all openings.
3. Remove grommets from inlet and outlet fittings.
4. Remove glovebox and lower instrument panel cover.
5. Disconnect electrical connectors at pressure switch and A/C harness.
6. Remove two nuts and four bolts securing cooling unit, then remove cooling unit.
7. Remove thermistor attaching screw and the thermistor.
8. Remove five clamps and three screws securing lower evaporator case, then remove lower case.
9. Remove two screws securing upper case, then remove upper case.
10. Remove heat insulator and clamp from outlet tube.
11. Disconnect liquid line tube from inlet fitting of expansion valve.
12. Disconnect expansion valve from inlet fitting of evaporator.
13. Reverse procedure to install, then evacuate and recharge system and check for leaks. If evaporator is replaced, add 1.4-1.7 oz. of new refrigerant oil to compressor.