Expansion valve replacement steps for LH vehicle:

1 – Prep:
Before you start, take the car to have the freon and oil removed from the AC system.
Unplug battery (negative)
Take pictures as you go, label things, go slow. Put each screw/bolt back in place after removing each item so as not to lose them.

 

Put shifter into Neutral – make sure your hand brakes are on!
remove the ashtray (2 screws) – unplug lighter before you remove
remove trim around shifter
remove black plastic trim by delicately sliding it towards back
remove the ski slope (2 wing nuts under slope) – unplug Sport switch SEE PIC (1)
remove center arm rest (2 screws)
remove box – unplug valet switch
remove rear center vent (push out) – unplug lighter
remove center instrument panel (6 screws) – unplug Radio, radio antennae, clock and AC control unit
remove center vent (it pops out) – don't pull out yet, you can't unplug it until you remove passenger side. Let it hang SEE PIC (4)
remove center console shell (2 screws accessible from where the center vent was SEE PIC (5), plus one screw totally in the back where the rear center vent was)
remove black plastic air ducts (one screw in rear SEE PIC (6))
remove metal/center plastic duct contraption (2 screws on top, two nuts on bottom) SEE PIC (7), (8), (9) and (10)

 

remove glove box assembly (take out screw 1 and 3 from inside top of glove box, screw on bottom left and screw on bottom right. There's a clip, be careful not to break it) – unplug it SEE PIC (11)
remove large black plastic air duct (one nut in middle holding a screw– it is square, do not lose it!)
unplug the center vent you had left hanging in step 2
remove air bag cover (2 screws on each bracket)
remove air bag assembly (4 bigger bolts) – unplug SEE PIC (12)
remove right vent (delicately push out from inside)
remove trim end (push clips from inside to prevent breakage)

 

remove kick panel (4 screws) – unplug aspirator SEE PIC (15)
remove plastic covers to light and cruise (2 tork screws each) – unplug SEE PIC (16)
remove large black plastic air duct (one screw in middle – it is square, do not lose it!)
remove instrument cluster (2 screws on each bracket) – unplug all, lift up
remove left vent (delicately push out from inside)
remove trim end (push clips from inside to prevent breakage) SEE PIC (17)

 

Unscrew 2 large nuts on each side, as well as 1 nut on bracket behind air bag assembly SEE PIC (18)
As you move dashboard towards you, it will be clear what needs to be unplugged. There is one set of wires you won't be able to remove on the passenger side. Just slide your dashboard that way and set it on the passenger seat while you work. That way, you won't have to cut anything. SEE PIC (19)

 

From engine compartment, on driver side, unhook heater hoses on driver side (1 screw each) SEE PIC (40)
From engine compartment, on passenger side, unhook AC lines to fire wall (1 bolt each) SEE PIC (41)
From inside the car, on driver side, remove air duct (4 screws) SEE PIC (42), (43) and (44)
From inside the car, on passenger side, remove air duct (4 screws) SEE PIC (45) and (46)
Remove Evaporator core assembly by doing the following:
remove 2 screws directly above the assembly SEE PIC (47)
remove 1 screw on each side, hidden behind insulation (remove insulation delicately first – it might tear), behind air ducts that you just removed SEE PIC (48)
remove 1 screw at the bottom, in the middle, where the radio would be
unhook 1 small flex hose from each side (they just slide out) SEE PIC (49)
unplug SEE PIC (50)
Wriggle free

 

Open Evaporator core assembly box
Remove control unit (3 screws)
Remove one of the 2 screws on the back of he box (either one, but not both until you understand how the pieces inside are connected) SEE PIC (51)
Remove little metal clips by inserting flat screwdriver in one end and gently pulling down (there are almost 20 of them, don't lose them, don't break them) SEE PIC (52)
Remove Evaporator
Remove expansion valve (unwrap first, then unhook) SEE PIC (53) – unwrap and unclip sensor

 

If you do not follow the following instructions, you may have done all this work for nothing:

Before you put in a new valve, you need to flush, clean and prep your AC system - 60 min
Remove cover over radiator and condenser (10 Tork screws) SEE PIC (60)
Unhook condenser (2 lines on passenger side)
Remove condenser (pull upwards) SEE PIC (62)
Remove dryer filter (1 tork screw on each bracket, unhook from both ends) SEE PIC (64)
Do the following with condenser, evaporator, and all lines in the system:
Blow air from one end and make sure air flows freely.
Pour AC cleaner ($17.50) into one end and blow air to flush it
Repeat procedure from other end
Repeat above steps until you are sure there are no more contamination into your system.
Whatever you do, do not pour chemicals into your compressor!

If your expansion valve was stuck because the dryer filter was blown (lots of little desiccant beads in your system, then CHANGE YOUR COMPRESSOR (about $210 new incl. Shipping).

Pour 2 oz oil into condenser
Attach new dryer filter (Use APCOAir 33494 - $20)
Pour 2 oz oil into evaporator
Attach new expansion valve (Use GPD 3411483 - $12)
Re-position condenser
Reattach all lines
Reattach cover over radiator – pay close attention to how the condenser is secured by its 2 prongs fitting into rubber grommets

 

If you want to replace the AC hoses as well, then you will need

MNA7340AB for the high side
MNA7310AC or MNA7310AD for the low side

Each hose is around $100 new on eBay, $30 used (if you're courageous).

 

Please note: when putting the evaporator core assembly back in, make sure you position the driver side first. It needs to slide a bit beneath the vent that you left in place, and it is a bit tricky if you haven't done this before. Feel the screw with your finger behind the plastic and guide it gently until the screw fits in the hole. Also, disassemble the vent duct that would connect it to the rest of the system on the driver side, and position the back first (2 screws), and then the front (2 more screws and 2 metal clips at the bottom). Later, remember to use a zip tie or something there to hold the wiring harness.

Do not over tighten anything, as you might have to do this again!

When all is back in place, go back to your AC place, and have them check for vacuum/pressure leaks, have them add 3.5 oz oil (for a total of 7.5) and 2lbs 7 oz of 134a freon.

Total DIY: between 5 and 6 hours, under $55 ($265 with compressor), not including AC shop fee and time.

Remember the dryer filter needs to be changed every 2 years per manufacturer's recommendation

 

1. Raise the front of the car
2. Unplug battery (negative)
3. Remove belt
From underneath the car, loosen the bolt on the face of the pulley located between the compressor and the main pulley (the smallest pulley)
Turn the screw (to the right to loosen, to the left to tighten – this is counter intuitive) at the bottom of that pulley
Remove belt
4. Remove compressor
Unplug electrical connection
Remove 2 hoses (1 screw each)
Remove 4 bolts from underneath car on side of compressor (the bolts are about 4” long and run the whole width of the compressor, as in a sleeve)

You might need the valve at top of compressor (4 bolts to remove), so be careful with it. Most replacement compressors will come with new O-rings and filled with about 2 oz. of oil, but you'll have to make sure of that, and you might have to re-use the valve.

When you put the new compressor back in place, you will have to slide one of the bolts in its “sleeve” before you position the compressor or you won't be able to put it in afterward (the other 3 shouldn't be a problem). Finally, spend the $20 and change the belt before reassembling.

 

Wow. I can't even get the valet and sport mode switches unplugged. What am I not seeing here?

 

You need to push down on the tab while you pull it out.

 

Thanks for your help. I got it. I wasn't using enough force as I'm terrified of braking things.
My evaporator is leaking so I'm doing the total R&R. I'm taking my time (probably a week) as I'm cleaning everything and doing a stereo install at the same time. Finding a few things that need attention- for example, five of the six tabs on the radio and climate control surround plastic were broken off.

 

I cannot get the air bag cover to budge. I removed all four bolts but something is hung up in the middle of the top edge. Any suggestions?

 

I know it sounds stupid, but did you unplug it? If the wire is still connected, it may not move much.

 

Thanks, I got it. The top edge fits pretty snugly over the round aluminum "hinge". I guess I'm just trying too hard not to break things.

 

Yes, sorry, I misread your original comment. I'm the one who feels stupid now. That said, be very careful with the plastic parts, they're not of the greatest quality (vents, bezels, etc), but the wood panels and such are sturdier.

 

Tell me about it- when I removed the "waterfall", five of the six tabs that hold the radio, clock, and HVAC controls were all broken. That said, I shall call you "Sir Guillaume" from this moment on if you can do this job in six hours. This photo is me at six hours- the dash is ready to lift out. Can't believe I haven't broken anything yet.

 

Sir Guillaume it is, because I can actually do this in less than 90 minutes now. And another 90 to put it back. I guess I did it so many times I can do it in my sleep. I certainly dream about it sometimes. Good luck with it, though.