Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Reposition the heater hoses for clearance.
3. Disconnect the vacuum hose from the brake booster and reposition.



4. Remove the evaporator outlet tube to thermal expansion valve (TXV) nut.
5. Disconnect the evaporator outlet tube from the TXV.
6. Disconnect the evaporator outlet tube from the evaporator inlet tube.
7. Remove and discard the sealing washers.

Important: Cap or tape the open A/C refrigerant tubes immediately to prevent contamination of the refrigerant system.

8. Cap or tape off the A/C refrigerant tubes.



9. Remove the TXV to evaporator bolts.
10. Remove the TXV from the evaporator core.
11. Remove and discard the sealing washers.
12. Cap or tape off the evaporator core.

1. Remove the cap or tape from the evaporator core.
2. Install the new sealing washers onto the evaporator core. Refer to Sealing Washer Replacement .



3. Install the TXV to the evaporator core.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the TXV to evaporator bolts.

Tighten
Tighten the bolts to 3.2 N·m (28 lb in).

5. Remove the cap or tape from the A/C refrigerant tubes.
6. Install the sealing washers onto the A/C refrigerant tubes. Refer to Sealing Washer Replacement .
7. Install the evaporator inlet tube to the evaporator outlet tube.
8. Install the evaporator outlet and inlet tubes to the TXV.



9. Install the evaporator outlet tube nut.

Tighten
Tighten the nut to 16 N·m (12 lb ft).

10. Connect the vacuum hose to the brake booster.
11. Reposition the heater hoses.
12. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
13. Leak test the fittings of the component using J 39400-A .