Air Conditioning Evaporator Thermal Expansion Valve Replacement 1st Design

Special Tools

J 39400-A Halogen Leak Detector

1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.



3. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
4. Remove and discard the seal washers.



5. Remove the TXV bolts.
6. Remove the TXV.
7. Remove and discard the seal washers.

1. Install new seal washers to the evaporator core fittings. Refer to Sealing Washer Replacement.
2. Install the TXV.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the TXV bolts.

Tighten
Tighten the bolts to 7 N·m (62 lb in).




4. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to Sealing Washer Replacement.
5. Install the condenser tube and evaporator hose to the TXV.
6. Install the TXV nut.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

7. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement.
8. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
9. Leak test the fittings using the J 39400-A .