Expansion Valve: Service and Repair

CAUTION:
- All SRS wire harnesses are covered with yellow insulation. Before you disconnect any part of an SRS wire harness, disconnect the airbag connectors.
- Whenever the ignition switch is ON (II), or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentally deploy and cause damage or injuries.
- For additional precautions, refer to Air Bags and Seat Belts.

1. Recover the refrigerant with a Recovery/Recycling/Charging System.





2. Disconnect the receiver line and the suction line from the evaporator.

NOTE: Plug or cap the lines immediately after disconnecting to avoid moisture and dust contamination into the system.

3. Remove the glove box.
4. Remove the glove box frame.





5. Disconnect the connector from the A/C thermostat.
Remove the four self-tapping screws, two mounting nuts and the mounting bolt.
Disconnect the drain hose, then remove the evaporator.





6. Pull out the A/C thermostat sensor from the evaporator fins.
7. Remove the self-tapping screws and clamps from the housings.
8. Carefully separate the housings, then remove the evaporator.
9. Remove the expansion valve.

NOTE: When loosening the expansion valve nuts, use a second wrench to hold the expansion valve or evaporator pipe. Otherwise, they can be damaged.

10. Assemble in the reverse order of disassembly. Make note of following items.
- Replace the 0-rings with new ones at each fitting, and apply a thin coat of refrigerant oil (Nippondenso: ND-OIL 8, P/N 38899 - PR7 - A01) before installing them.

NOTE: Be sure to use the right 0-rings for HFC-134a (R-134a) to avoid leakage.

- Install the expansion valve capillary tube with the capillary tube in contact with the suction line directly, and wrap it with tape.
- Reinstall the A/C thermostat sensor to its original location.

11. Install in the reverse order of removal. Make note of the following items.
- If you're installing a new evaporator, add refrigerant oil.
- Replace the 0-rings with new ones at each fitting, and apply a thin coat refrigerant oil before installing them.
- Apply sealant to the grommets.
- Make sure that there is no air leakage.
- Charge the system, and test its performance.