Expansion Valve: Service and Repair

Fig. 4 Exploded view of evaporator & heater core.:

Fig. 5 Exploded view of instrument panel assembly.:

EVAPORATOR CORE AND / OR EXPANSION VALVE

1. Disconnect battery ground cable and discharge A/C system.
2. Working from engine compartment, disconnect refrigerant lines from evaporator Fig. 4, then plug lines and open fittings.
3. Remove instrument cluster and satellite switch assembly, refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Service and Repair
4. Remove engine hood lock release lever.
5. Remove shifter knob and trim panels as needed, then the front console assembly Fig. 5.
6. Remove radio bracket with radio, disconnecting electrical connectors to radio, clock and antenna.
7. Remove knee pad, then remove instrument panel front cover by pulling lower end of cover toward the rear then move the cover upward.
8. Remove windshield pillar trim and instrument panel grilles, Fig. 5.

Fig. 3 Exploded view of evaporator core.:

Fig. 6 Exploded view of evaporator core.:

9. Remove nuts and bolts securing instrument panel, Fig. 3, then remove instrument panel and glove box. Refer to Fig. 4, for evaporator case removal.
10. Disconnect electrical connectors from resistor and thermostat, release harness from retainers and secure aside.
11. Remove evaporator case retaining nuts, then the evaporator case, taking care not to damage inlet and outlet tubes. Refer to Fig. 6, for evaporator case disassembly.
12. Remove resistor, insulator and thermostat.
13. Remove retaining clips, then separate upper and lower case halves.
14. Remove drain hose and evaporator case grommets.
15. Remove screw and clip securing expansion valve sensor to evaporator, taking care not to damage sensor tube.
16. Disconnect expansion valve from evaporator inlet, and remove valve along with inlet tube and O-rings.
17. Lift evaporator from lower case.
18. Reverse procedure to install, noting the following:
a. If evaporator is being flushed or replaced, add 1.7 oz. new refrigeration oil to evaporator prior to installation.
b. Use new O-rings, lightly lubricated with refrigeration oil, when installing expansion valve and connecting lines.
c. Ensure that case seals and seals around evaporator and heater core tubes are properly positioned.

19. Evacuate and recharge A/C system, then check for leaks.