Chrysler Caravan/Voyager/Town n Country 1984-1995

Expansion Valve (H-Valve)

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TESTING



  1. Connect a manifold gauge set or charging station to the air conditioning system. Verify adequate refrigerant level.
  2.  
  3. Disconnect and plug the vacuum hose at the water control valve.
  4.  
  5. Disconnect the low pressure or differential pressure cut off switch connector and jump the wires inside the boot.
  6.  
  7. Close all doors, windows and vents to the passenger compartment.
  8.  
  9. Set controls to MAX A/C , full heat and high blower speed.
  10.  
  11. Start the engine and hold the idle speed at 1000 rpm. After the engine has reached normal operating temperature, allow the passenger compartment to heat up to create the need for maximum refrigerant flow into the evaporator.
  12.  
  13. The discharge (high pressure) gauge should read 140-240 psi (965-1655 kPa) and suction (low pressure) gauge should read 20-30 psi (138-207 kPa), providing the refrigerant charge is sufficient.
  14.  
  15. If the suction side is within specifications, freeze the expansion valve control head using a very cold substance (liquid CO2 or dry ice) for 30 seconds:
    1. If equipped with a silver H-valve used with fixed displacement compressor, the suction side pressure should drop to 15 in. Hg (50 kPa) vacuum. If not, the expansion valve is stuck open and should be replaced.
    2.  
    3. If equipped with a black H-valve used with variable displacement compressor, the discharge pressure should drop about 15 percent. If not, the expansion valve is stuck open and should be replaced.
    4.  

  16.  
  17. Allow the expansion valve to thaw. As it thaws, the pressures should stabilize to the values in Step 7. If not, replace the expansion valve.
  18.  
  19. Once the test is complete, put the vacuum line and connector back in the original locations, and perform the overall performance test.
  20.  

REMOVAL & INSTALLATION



1984-91 Models

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Expansion valve-1984-91 Models

  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. Disconnect the low or differential pressure cut off switch.
  6.  
  7. Remove the attaching bolt at the center of the refrigerant plumbing sealing plate.
  8.  
  9. Pull the refrigerant lines assembly away from the expansion valve. Cover the exposed ends of the lines to minimize contamination.
  10.  
  11. Remove the 2 Torx® screws that mount the expansion valve to the evaporator sealing plate.
  12.  
  13. Remove the valve and discard the gaskets.
  14.  

To install:
  1. Transfer the low pressure cutoff switch to the new valve, if necessary.
  2.  
  3. Coat the new "figure-8" gasket with wax-free refrigerant oil and install to the evaporator sealing plate.
  4.  
  5. Install the expansion valve and torque the Torx® screws to 100 inch lbs. (11 Nm).
  6.  
  7. Lubricate the remaining gasket and install with the blower motor lead under the right side of the instrument panel.
  8.  
  9. Connect the refrigerant lines and sealing plate, tighten to 17 ft. lbs. (23 Nm).
  10.  
  11. Connect the electrical leads and connect the negative battery cable.
  12.  
  13. Have the system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment.
  14.  

1991-95 Models

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Expansion valve-1992-95

  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. Disconnect the boot-type wire connector from pressure cut off switch.
  6.  
  7. Disconnect the 3-pin connector from the ECCS.
  8.  
  9. Remove the attaching bolt at the center of the refrigerant plumbing sealing plate.
  10.  
  11. Pull the refrigerant lines assembly away from the expansion valve. Cover the exposed ends of the lines to minimize contamination.
  12.  
  13. Remove the 2 screws that mount the expansion valve to the evaporator sealing plate.
  14.  
  15. Remove the valve and discard the gaskets.
  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. Connect the electrical leads and connect the negative battery cable.
  10.  
  11. Have the system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment.
  12.  

 
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