Hi there!
Getting ready for summer I see!

The expansion valve is accessed from the left side of the passenger side foot well.
No need to remove the dash!
It will be on the smaller line coming through the firewall.

Note the location of the sensing bulb location on the return line. It needs to go back there for sure or a little farther away I have found works a wee bit better.

On a horizontal line is goes at a 45 degree angle from the bottom. Anywhere "around" on a vertical section of line. Oil travels on the bottom of lines and you want to sense the gas!

Insulate everything as it all gets cold and sweats moisture out of the air.


I take it that the compressor locked up and that is why the clutch smoked!

The need to remove the expansion valve is because, in all likelihood, there are metal particles spread throughout the system.
If the dryer screens missed any, the expansion valve can get plugged up.

You will have to flush about a quart in to rinse out all the lines in the system or the warranty will not be any good on that new compressor.

While you have the compressor out, the dryer out and the expansion valve out, that is when you push a solvent through the lines.
Some people use refrigerant to push with but any dry (free of moisture) inert gas like nitrogen, argon or helium for example, can be used if you are a welder type dude!.
Even propane if one uses some thinking and exercise extreme caution of where it comes out in the rags.

Did they sell you some of that as well?
If they did not, keep your receipt from whomever you purchase solvent from.
You use it to prove that you did this very important part of the repair!

The six ounces of compressor oil will be enough for the system as the system is sized for that compressor or vice versa.
Whatever refrigerant you are using, you have to have a compatible oil in that compressor. Don't forget to put it in!

Did the compressor come with a bottle of oil?

Do you have a vacuum pump for the evacuation & leak test phase before recharging?

While you are taking things apart look for any places that show an "oil sweating" joint or surface! That may help you find where the leak was!

I looked for a long time for a leak. I found mine under the clamp that hold the dryer/receiver canister.
Volvo had put rubber under it to reduce possible noise but instead it held moisture there.
Don't use a foam type rubber if you need a spacer!
Pin hole rust leak!

That's about all I can think of of the top of my head.
Hope this helps!

Phil