This procedure involves recovering refrigerant, removing the AC evaporator housing assembly to access the expansion valve (TXV), replacing the valve with new O-rings, and recharging the system.

Warnings

Tools required

Parts

• AC expansion valve (TXV) × 1 — Use OEM specification
• AC line O-rings (various sizes) × 1 — Use OEM specification
• R-134a refrigerant × 1 — Approximately 1.43 lbs (650g)
• PAG oil (ND-12) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and set parking brake
2. Turn off ignition and remove key
3. Allow AC system to reach ambient temperature if recently operated
4. Disconnect negative battery terminal and wait 3 minutes for airbag system discharge
5. Place protective covers over front seats and floor mats
6. Gather all replacement parts and verify correct expansion valve type for 2.5L AWD model

Procedure

1. 1

   Recover AC refrigerant
   Connect AC recovery machine to high and low side service ports. Follow machine instructions to completely recover all refrigerant from the system. Record the amount recovered for comparison during recharge. Verify system is at 0 PSI before proceeding.
   ⚠️Never open AC system without proper refrigerant recovery. Releasing refrigerant is illegal and environmentally harmful.
2. 2

   Remove lower dashboard panels
   Remove the lower driver side dashboard panel by releasing clips and removing mounting screws. Remove the lower passenger side panel and glove box assembly. Remove center console lower trim if necessary for access. Set all panels aside in organized manner for reassembly.
3. 3

   Disconnect evaporator electrical connections
   Locate the evaporator temperature sensor connector on the evaporator case. Press the release tab and disconnect. Disconnect the blower motor connector and any other electrical connections to the HVAC unit. Label all connections for proper reassembly.
4. 4

   Disconnect AC lines at firewall
   From the engine bay, locate the AC line connections at the firewall near the evaporator inlet and outlet. Use flare nut wrenches to carefully disconnect both the liquid line and suction line fittings. Immediately cap all open ports with plugs to prevent moisture and debris entry. Discard old O-rings.
   ⚠Use two wrenches (one to hold, one to turn) to prevent line damage. Do not allow lines to twist.
5. 5

   Remove evaporator mounting bolts
   Locate the evaporator housing mounting bolts accessible from inside the vehicle. Remove all mounting bolts securing the evaporator case to the firewall and body structure. Support the evaporator housing as you remove the final bolts.
6. 6

   Remove evaporator housing
   Carefully lower and remove the evaporator housing assembly from under the dashboard. This may require maneuvering around steering column and other components. Work slowly to avoid damaging surrounding components. Place housing on clean work surface.
7. 7

   Disassemble evaporator housing
   Remove the screws securing the evaporator housing halves together. Carefully separate the housing to expose the evaporator core and expansion valve. Note the orientation of all components for reassembly. The expansion valve is typically mounted on the evaporator inlet.
8. 8

   Remove old expansion valve
   Locate the expansion valve (TXV) attached to the evaporator inlet line. Remove the mounting bolt securing the valve. Carefully disconnect the valve from both the inlet line and evaporator core. Remove and discard old O-rings from all connection points. Inspect evaporator inlet tube for damage or blockage.
   ℹ️Note the orientation of the expansion valve sensing bulb and capillary tube position for correct installation.
9. 9

   Install new expansion valve
   Install new O-rings on all connection points, lightly coating with fresh PAG oil (approximately 1-2ml per O-ring). Position the new expansion valve with sensing bulb in same orientation as original. Connect valve to evaporator inlet and outlet, ensuring O-rings seat properly. Install and torque mounting bolt to specification.
10. 10

    Reassemble evaporator housing
    Verify all internal components are properly positioned. Align the evaporator housing halves and secure with screws to specification. Ensure housing seals properly with no gaps that could cause air leaks.
11. 11

    Reinstall evaporator assembly
    Maneuver the evaporator housing back into position under the dashboard. Align mounting points and install all mounting bolts finger-tight first, then torque to specification. Reconnect all electrical connectors using your labels from disassembly.
12. 12

    Reconnect AC lines at firewall
    Install new O-rings on both AC line fittings, coating lightly with PAG oil. Connect liquid line and suction line to evaporator connections at firewall. Hand-tighten fittings first to ensure proper threading, then torque to specification using flare nut wrenches.
    ⚠Cross-threading AC fittings will require expensive line replacement. Ensure proper alignment before tightening.
13. 13

    Evacuate AC system
    Connect vacuum pump to AC service ports. Evacuate system to at least 29 inches of mercury vacuum. Hold vacuum for minimum 30 minutes to verify no leaks and remove all moisture. If vacuum does not hold, locate and repair leak before proceeding.
    ℹ️Proper evacuation is critical to remove moisture that causes system corrosion and poor performance.
14. 14

    Recharge AC system
    Using refrigerant scale and recharge machine, add the correct amount of R-134a refrigerant (approximately 1.43 lbs/650g - verify on underhood label). Add appropriate amount of PAG oil if required by total amount removed during service (typically 30-50ml for expansion valve replacement). Monitor pressures during recharge.
15. 15

    Reinstall interior panels
    Reinstall all dashboard panels, glove box, and trim pieces in reverse order of removal. Ensure all clips are fully seated and screws are tightened to specification. Reconnect negative battery terminal.

Reassembly

1. Double-check that all electrical connectors are fully seated with positive clicks
2. Verify all dashboard panels are secure with no rattles or gaps
3. Ensure no tools or parts were left in the HVAC system or dashboard area

Verification

• Start engine and turn AC to maximum cold, high fan speed
• Use leak detector to check all AC line connections for refrigerant leaks
• Verify vent temperature reaches 38-45°F within 5 minutes of operation
• Check that AC pressures are within specification (typically 25-35 PSI low side, 200-250 PSI high side at idle, ambient 80°F)
• Operate AC through all modes (defrost, floor, vent) to verify proper airflow distribution
• Listen for unusual noises from expansion valve or evaporator area
• Verify no refrigerant odor in cabin during operation

More procedures for this vehicle