Chrysler Caravan/Voyager/Town n Country 1984-1995

Expansion Valve

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REMOVAL & INSTALLATION



  1. Have the system discharged by a qualified professional mechanic using an approved recovery/recycling machine.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the middle bench, if equipped. Remove the interior left lower quarter trim panel.
  6.  
  7. Remove the 7 screws that attach the air distribution duct to the floor and unit. Pull the distribution duct straight up to remove.
  8.  
  9. Remove the 6 screws from the top surface of the unit and remove the unit cover.
  10.  
  11. Remove the bolt that secures the refrigerant lines to the evaporator sealing plate and separate the parts. Discard the gasket. Cover the exposed ends of the lines to minimize contamination.
  12.  
  13. Pull the evaporator and expansion valve straight up in order to clear the extension tube pilots and remove from the vehicle. Cover the exposed ends of the lines to minimize contamination.
  14.  
  15. Remove the Torx® screws and remove the expansion valve from the evaporator. Discard the gasket.
  16.  

To install:
  1. Remove and replace the aluminum gasket on the evaporator sealing plate.
  2.  
  3. Carefully hold the expansion valve sealing plate and torque the 2 screws to 100 inch lbs. (11 Nm).
  4.  
  5. Remove and replace the aluminum gasket on the refrigerant line sealing plate.
  6.  
  7. Connect the refrigerant lines and sealing plate, tighten to 17 ft. lbs. (23 Nm).
  8.  
  9. Install the unit cover and air distribution duct.
  10.  
  11. Install the interior trim cover and middle bench.
  12.  
  13. Have the system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment.
  14.  
  15. Connect the negative battery cable and check the entire climate control system for proper operation and leaks.
  16.  

 
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