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For 1990-2009 cars only

Air Conditioning Evaporator Thermal Expansion Valve Replacement 1st Design

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

  2. Object Number: 872539  Size: SH
  3. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
  4. Remove and discard the seal washers.

  5. Object Number: 872568  Size: SH
  6. Remove the TXV bolts.
  7. Remove the TXV.
  8. Remove and discard the seal washers.

Installation Procedure


    Object Number: 872568  Size: SH
  1. Install new seal washers to the evaporator core fittings. Refer to Sealing Washer Replacement .
  2. Install the TXV.
  3. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the TXV bolts.
  5. Tighten
    Tighten the bolts to 7 N·m (62 lb in).


    Object Number: 872539  Size: SH
  6. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to Sealing Washer Replacement .
  7. Install the condenser tube and evaporator hose to the TXV.
  8. Install the TXV nut.
  9. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

  10. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  11. Leak test the fittings using the J 39400-A .

Air Conditioning Evaporator Thermal Expansion Valve Replacement 2nd Design

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

  2. Object Number: 1884861  Size: SH
  3. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
  4. Remove and discard the seal washers.

  5. Object Number: 872568  Size: SH
  6. Remove the TXV bolts.
  7. Remove the TXV.
  8. Remove and discard the seal washers.

Installation Procedure


    Object Number: 872568  Size: SH
  1. Install new seal washers to the evaporator core fittings. Refer to Sealing Washer Replacement .
  2. Install the TXV.
  3. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the TXV bolts.
  5. Tighten
    Tighten the bolts to 7 N·m (62 lb in).


    Object Number: 1884861  Size: SH
  6. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to Sealing Washer Replacement .
  7. Install the condenser tube and evaporator hose to the TXV.
  8. Install the TXV nut.
  9. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

  10. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  11. Leak test the fittings using the J 39400-A .