GM Service Manual Online
For 1990-2009 cars only

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure


    Object Number: 802735  Size: SH
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the instrument panel (I/P) carrier. Refer to Refrigerant Recovery and Recharging .
  3. Remove the insulation (1) from the thermal expansion valve (TXV). Discard the used insulation.

  4. Object Number: 817514  Size: SH
  5. Remove the HVAC line clamp screw.

  6. Object Number: 817516  Size: SH
  7. Remove the HVAC line clamp.

  8. Object Number: 802742  Size: SH
  9. Remove the bolts (1) that secure the TXV to the evaporator.

  10. Object Number: 802746  Size: SH
  11. Remove the TXV line bracket.

  12. Object Number: 2013305  Size: SH
  13. Remove the TXV from the evaporator core.
  14. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.

  15. Straightly pull the TXV out from the A/C lines.
  16. Remove the thermal expansion valve.
  17. Remove and discard the O-ring seals. Refer to O-Ring Replacement .

Installation Procedure


    Object Number: 2013305  Size: SH
  1. Lubricate the O-rings. Refer to O-Ring Replacement .
  2. Install the A/C lines into the TXV.
  3. Carefully slide the TXV onto the evaporator core until seated.

  4. Object Number: 802746  Size: SH
  5. Install the TXV line bracket.
  6. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 802742  Size: SH
  7. Install the bolts (1) that secure the TXV to the evaporator.
  8. Tighten
    Tighten the bolt to 3.5 N·m (31 lb in).


    Object Number: 817516  Size: SH
  9. Install the HVAC line clamp.

  10. Object Number: 817514  Size: SH
  11. Install the HVAC line clamp screw.
  12. Tighten
    Tighten the screw to 1 N·m (9 lb in).


    Object Number: 802735  Size: SH
  13. Install new insulation (1) onto the lines and TXV.
  14. Install the instrument panel carrier. Refer to Refrigerant Recovery and Recharging .
  15. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .