Toyota 88515-22240
Expansion Valve

Service and repair of expansion valves requires first removing fridge refrigerant before separating liquid tubes and suction pipes from the A/C device. The expansion valve must be removed first by loosening the piping clamp followed by gentle packing pry-out and bolt removal from the evaporator with a hexagon wrench. Start by lubricating four new O-rings of the expansion valve with compressor oil before installing the liquid tube and suction tube to the device. When installing new packing on the expansion valve you should first cut off and peel back the packing paper while making sure the paper remains visible through the tube side hole and then set the packing without excess tape extending past the expansion valve edge. Apply compressor oil to 2 new O-rings and attached them to the expansion valve before tightening the 2 bolts to 5.4 Nm and 55 kg.cm and 48 in.lb. Realignment of the blower unit should be followed by glove compartment placement before connecting liquid and suction tubes to the A/C unit followed by air evacuation from the refrigeration system then add 800 plus or minus 50 g (28.22 plus or minus 1.76 oz.) of refrigerant. Use gas leak detection equipment to search for refrigerant escape from the system after which you should verify that all junctions maintain proper torque values.

The service process for the expansion valve begins with refrigerant evacuation from the system through the use of liquid and suction tubes which should later be disconnected from the A/C unit. Detach the blower unit first by removing the piping clamp then carefully extract the packing because it cannot be reused before using a hexagon wrench to remove the 2 bolts separating the expansion valve from the evaporator. Attach the liquid tube and suction tube to the expansion valve after applying compressor oil to four new O-rings before installation. Apply new packing to the expansion valve by removing and peeling the packing paper then position it with bolt hole visible while placing it without tape beyond the expansion valve edges. Use 2 bolts to fasten the expansion valve but tighten them to 5.4 N.m (55 kgf.cm, 48 in.lbf) while inspecting for evaporator interference and applying compressor oil to 2 new O-rings before their installation. The technician must reinstall the blowers and glove compartment before connecting liquid and suction tubes to the A/C unit and follows vacuum evacuation then fills the system with 800 plus or minus 50 g (28.22 plus or minus 1.76 oz.) of refrigerant. End the inspection by using a gas leak detector to find refrigerant losses and aligning joint torques when leakages occur.

Using a hexagon wrench unscrew two evaporator and tubes securing bolts on the expansion valve by applying torque up to 5.4 Nm (55 kg.cm, 48 in.lb). The installation requires compressor oil lubrication of 4 new O-rings before placing them on the tube and valve before reinstallation follows the reverse order of disassembly.

The expansion valve requires two main steps for servicing: first discharge the refrigerant through the refrigeration system followed by disconnecting the liquid and suction tubes from the A/C unit. Remarkable service requires you to extract these elements by pulling out the packing material while employing a 5.0 mm hexagon wrench for bolt detachment from two points and tube separation. Immediately protect open fittings from moisture and dirt intrusion. You need to apply ND-OIL 8 or equivalent compressor oil to two new O-rings before installing them on the valve before attaching the tube with its accessory to the expansion valve. The installation bolt hole must remain visible on the tube side by leaving packing paper untaped while you apply the packing to the expansion valve so it extends only to its edge. Two new O-rings require lubrication with compressor oil before they are installed on the evaporator using a 5.0 mm (0.20 in.) hexagon wrench and 2 bolts. Apply torque force of 5.4 Nm (55 kg.cm, 48 in.lb) but avoid packing material from jamming against the evaporator. The expansion valve requires additional packing paper removal before receiving its packing application. Installation of the blower unit should be followed by connecting liquid and suction tubes to the A/C system before charging the unit with refrigerant beginning with air evacuation and using an 800 plus or minus 50 g (28.22 plus or minus 1.76 oz.) amount. Gas leak detection should be performed to check for refrigerant loss followed by checking pipe joint and clamps for proper torque when leakage is discovered.

Before servicing or repairing the Expansion Valve you must uninstall the evaporator which requires a hexagon wrench to loosen the two securing bolts on the valve and evaporator tubes with 5.4 N.m (55 kgf.cm, 48 in.lbf) torque setting. The installation procedure demands compressor oil application to 4 new O-rings before reuniting tubes and valve to their proper positions while adhering to the removal reverse sequence.