Expansion Valve: Service and Repair
THERMAL EXPANSION VALVE (TXV)TOOLS REQUIRED
^ J 44655 TXV Installation Tool
REMOVAL
IMPORTANT: Verifying the purity of the refrigerant with a purity identifier before recovery is recommended.
1. Recover refrigerant using an approved refrigerant recovery system. Measure the amount of oil lost during recovery and record.
CAUTION: DO NOT REMOVE HOSES OR LINES BEFORE SYSTEM IS FULLY DISCHARGED.
NOTE: When removing the TXV, keep dirt and foreign material from getting on or into the O-ring sealing surfaces. Clean tools and a clean work area are important for proper service. The TXV seal area should be cleaned before any repairs are performed. The parts must be kept clean at all times and any parts to be assembled should be cleaned with a non-petroleum based solvent and dried with air. Use only lint free cloths to wipe parts. Do not allow solvent to enter evaporator or hoses.
IMPORTANT: On earlier vehicles a bolt was used instead of a stud/nut.
2. Remove suction/liquid line block-to-TXV retaining nut.
3. Remove suction/liquid line block from TXV by gently rocking while pulling forward.
4. Install cap on suction/liquid line assembly to prevent oil spillage.
5. Remove TXV retaining bolts.
6. On earlier vehicles, install suction/liquid line assembly to TXV bolt hand tight into TXV.
7. Using bolt or stud as a handle, remove TXV from evaporator by gently rocking TXV while pulling forward in vehicle.
8. Using fingers or a plastic tool, remove O-rings from evaporator pipes. Use a mirror to view O-rings on evaporator core.
INSTALLATION
1. Install new O-rings to evaporator pipes.
CAUTION: BLOWER RESISTOR CARD HAS SHARP EDGES AND MAY BE VERY HOT IF BLOWER WAS USED PRIOR TO SERVICING.
2. Install TXV using TXV Installation Tool J 44655 to support evaporator pipes and mounting flange while installing TXV.
2.1 Orient TXV with dome-shaped end toward passenger side of vehicle.
2.2 Install cap screws through T-handle and through TXV.
2.3 Thread (2) cap screws into evaporative core flange
2.4 Pull T-handle back against cap screws and carefully install and seat TXV into position.
2.5 Carefully remove cap screws and T-handle.
3. Apply a thin coating of clean mineral oil on TXV to evaporator O-ring surfaces.
IMPORTANT: On earlier vehicles a bolt was used instead of a stud/nut.
4. Insure TXV is completely installed, TXV should be almost flush with edge of bevel of TXV foam seal.
NOTE: Improper installation of TXV to evaporator pipes will damage pipes and require evaporator core replacement.
5. Thread TXV to evaporator core block bolts into block by hand. Bolts should thread in easily. Do not force! If bolts do not thread in easily, verify that TXV is properly installed onto both pipes and fully seated to block.
6. After verifying proper installation, tighten both TXV to block bolts.
Torque:
TXV-to-Block Bolts: 7 N.m (62 in-lbs)
7. Thoroughly clean the O-ring surfaces of the TXV.
8. Install new O-rings to suction/liquid line assembly block.
9. Lubricate the O-rings with clean mineral oil.
10. Install suction/liquid line assembly block to TXV.
IMPORTANT: On earlier vehicles a retainer bolt was used instead of a stud/nut.
11. Install suction/liquid line assembly to TXV nut.
Torque:
Suction/Liquid Line Assembly-to-TXV Bolt: 7 N.m (62 in-lbs)
12. Evacuate, charge, and leak check the A/C system.