GM Service Manual Online
For 1990-2009 cars only

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

  1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
  2. Remove the instrument panel (I/P) carrier. Refer to Instrument Panel Carrier Replacement .

  3. Object Number: 802735  Size: SH
  4. Remove the insulation (1) from the thermal expansion valve (TXV).

  5. Object Number: 1379014  Size: SH
  6. Remove the HVAC line clamp screw.
  7. Remove the HVAC line clamp.

  8. Object Number: 1379012  Size: SH
  9. Remove the TXV to evaporator bolts.
  10. Remove the TXV line bracket.

  11. Object Number: 1379008  Size: SH
  12. Remove the TXV from the evaporator core.
  13. Disconnect the TXV from the A/C lines by pulling straight out.
  14. Remove the TXV.
  15. Remove and discard all O-rings.

Installation Procedure


    Object Number: 1379008  Size: SH
  1. Install new O-rings. Refer to O-Ring Replacement .
  2. Install the A/C lines into the TXV.
  3. Install the TXV onto the evaporator core.

  4. Object Number: 1379012  Size: SH
  5. Install the TXV line bracket.
  6. Notice: Refer to Fastener Notice in the Preface section.

  7. Install the TXV to evaporator bolts.
  8. Tighten
    Tighten the bolts to 3.5 N·m  (31 lb in).


    Object Number: 1379014  Size: SH
  9. Install the HVAC line clamp.
  10. Install the HVAC line clamp screw.
  11. Tighten
    Tighten the screw to 1 N·m  (9 lb in).


    Object Number: 802735  Size: SH
  12. Install the insulation (1) onto the lines and TXV.
  13. Install the instrument panel (I/P) carrier. Refer to Instrument Panel Carrier Replacement .
  14. Evacuate the A/C system. Refer to Refrigerant Recovery and Recharging .
  15. Leak test the fittings of the component using J 39400-A .