ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Expansion Valve

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REMOVAL & INSTALLATION



The refrigerant must be recovered by a licensed repair shop. Please refer to General Information & Maintenance of this manual before discharging/recovering the A/C system or disconnecting air conditioning lines.

To remove the expansion valve, the evaporator assembly must be removed from under the dash. This is a very involved procedure and should be review before proceeding. The following procedure may need to be altered, depending on the vehicle and interior options. You may find it necessary to remove additional components to make air conditioning service easier. Center consoles, seats, glove box, storage areas and floor gear shift levers are all components that may or may not interfere with extracting the evaporator assembly from under the dash.

  1. The refrigerant must be recycled at a licensed recovery station, as outlined in General Information & Maintenance .
  2.  
  3. Disconnect the negative (-) battery cable.
  4.  
  5. Disconnect and plug the inlet and outlet pipe from the evaporator.
  6.  


WARNING
When refrigerant lines are disconnected you must IMMEDIATELY cap all openings to prevent the entry of moisture in the system resulting in contamination and corrosion of internal components. ALSO, minimize the amount of time that the system remains discharged by planning the job well before hand. No matter how well you cap the lines, some moisture is bound to enter and damage the system over time if it remains in a discharged state.

  1. Remove the glove box and disconnect the thermoswitch wire.
  2.  
  3. Disconnect the defroster hose and remove the evaporator housing retaining nuts and bolts. Remove the evaporator assembly, being careful not to damage the seals.
  4.  
  5. Remove the housing retaining clips and split the housing in two. Be careful not to damage the seals.
  6.  
  7. Using a backup and flare nut wrench, remove the expansion valve.
  8.  

To install:
  1. Using a backup and flare nut wrench, install the expansion valve.
  2.  
  3. Install the housing halves and retaining clips. Be careful not to damage the seals.
  4.  
  5. Install the evaporator housing and connect the defroster hose. Be careful not to damage the seals.
  6.  
  7. Install the glove box and connect the thermoswitch wire.
  8.  
  9. Connect the inlet and outlet pipe to the evaporator.
  10.  
  11. Evacuate, leak test and charge the air conditioning system as outlined in General Information & Maintenance . If installing a new condenser, it is necessary to replace approximately 1 ounce of refrigerant oil.
  12.  

After you have made repairs you should take the vehicle to a licensed air conditioning technician to have the system tested for leaks then recharged. Newer air conditioning systems equipped with R134a refrigerant are NOT compatible with R-12 refrigerant.

  1. Connect the negative (-) battery cable and check operation.
  2.  

 
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