CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the REFRIGERANT OIL CAPACITIES to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is disconnected from the expansion valve, or if the expansion valve is removed. Failure to replace the rubber O-ring seals may result in a refrigerant system leak.

NOTE: LHD model shown in illustrations. RHD model similar.

Fig. 269: Front Expansion Valve Removal/Installation

1. Remove the tape or plugs from the opened refrigerant fittings and all expansion valve and evaporator ports.

2. Lubricate new O-ring seals with clean refrigerant oil and install them onto the refrigerant line and evaporator tube fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

3. Install the A/C expansion valve (2) onto the evaporator tube tapping block (3)

4. Install the two bolts (1) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 N.m (97 in. lbs.).

Fig. 270: Liquid & Suction Line Assembly Removal/Installation

5. Connect the A/C liquid and suction line assembly (1) to the A/C expansion valve (4).

CAUTION: Use care when installing the A/C lines to the A/C expansion valve.

Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur.

6. Install the nut (5) that secures the A/C liquid and suction line assembly to the A/C expansion valve.

Tighten the nut to 20 N.m (15 ft. lbs.).

7. Install the nut (6) that secures the refrigerant line retaining bracket to the stud (2) located on the right front strut tower. Tighten the nut securely.

Fig. 271: Heat Shield - Unified Line

8. If equipped, position the heat shield (3) onto the three studs (1) located on the dash panel in the engine compartment and install the three retaining nuts (2). Tighten the nuts to 1 N.m (10 in. lbs.).

9. Reconnect the negative battery cable.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage.

10. Evacuate the refrigerant system.

11. Adjust the refrigerant oil level.

12. Charge the A/C system.