Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Expansion Valve

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REMOVAL & INSTALLATION



Except Justy

See Figures 1 and 2

Click image to see an enlarged view

Fig. Fig. 1: Evaporative core and expansion valve-Sedan, Coupe, Loyale, XT, Wagon and Brat



Click image to see an enlarged view

Fig. Fig. 2: Evaporative core and expansion valve-Legacy, Impreza and SVX

The expansion valve is located inside the evaporator case attached to the evaporator core.

  1. Disconnect the negative battery cable.
  2.  
  3. Properly discharge the air conditioning system using an approved recovery/recycling machine.
  4.  
  5. Disarm the air bag on equipped models.
  6.  
  7. Disconnect and plug the refrigerant lines at the evaporator.
  8.  
  9. Disconnect the air bag harness routed in front of the evaporative case on equipped models.
  10.  
  11. Remove the glove box and support brackets.
  12.  
  13. Loosen and remove the evaporator case retainer bands or nut and bolts.
  14.  
  15. Disconnect the harness attached to the case assembly.
  16.  
  17. Disconnect the drain hose and remove the evaporator assembly.
  18.  
  19. Remove the evaporator case attaching clips.
  20.  
  21. Separate the case halves and remove the evaporator.
  22.  
  23. Separate the expansion valve from the evaporator line, being careful not to bend or distort the line. Remove and discard the O-ring.
  24.  

To install:
  1. Connect the expansion valve to the evaporator assembly, using a new O-ring coated with clean refrigerant oil. Tighten the retainer nut to 14-22 ft. lbs. (20-29 Nm).
  2.  
  3. Install the evaporator assembly into the case halves.
  4.  
  5. Secure evaporator case assembly together using the retainer clips.
  6.  
  7. Install the evaporator assembly and connect drain hose.
  8.  
  9. Connect the case wire harness. Connect the air bag harness routed in front of the evaporative case assembly.
  10.  
  11. Install the evaporator housing securing bands or nut and bolts.
  12.  
  13. Install the glove box assembly.
  14.  
  15. Reconnect the refrigerant lines at the evaporator case. Tighten the suction hose-to-the evaporator to 7 ft. lbs. (10 Nm) and the receiver pip-to-evaporator to 18 ft. lbs. (25 Nm).
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Charge, evacuate and leak test the air conditioning system using an approved recovery/recycling machine.
  20.  

Justy

Consult an authorized Subaru dealer for expansion valve removal and installation. Because the A/C system on the Justy is a dealer installed option, many locations and installation variations may occur.

 
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