GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Uplander Ext. 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement

Special Tools

J-39400-A Halogen Leak Detector

Removal Procedure
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the left lower quarter trim panel. Refer to Rear Quarter Trim Panel Replacement - Left Side .
  3. Remove the foam wrap from the auxiliary thermal expansion valve (TXV).

    4. Object Number: 882517 Size: SH
  4. Remove the auxiliary TXV line clamp screws.
  5. Remove the auxiliary TXV line clamp from the HVAC module assembly.

    6. Object Number: 882519 Size: SH
  6. Remove the bolt from the auxiliary TXV line block fitting.
  7. Remove the A/C lines from the auxiliary TXV.
  8. Remove and discard the sealing washers.

    9. Note: Cap or tape the open A/C refrigerant lines immediately to prevent contamination of the refrigerant system.

  9. Cap or tape the A/C lines.

    10. Object Number: 882523 Size: SH
  10. Remove the auxiliary TXV to evaporator core bolts.
  11. Remove the auxiliary TXV from the evaporator core.
  12. Cap or tape off the evaporator core lines.
  13. Remove and discard the sealing washers.

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

    3. Object Number: 882523 Size: SH
  3. Install the auxiliary TXV to the evaporator core.

    4. Caution: Refer to Fastener Caution in the Preface section.

  4. Install the auxiliary TXV to the evaporator core mounting bolts and tighten to 3.5 N·m (31 lb in) .
  5. Remove the cap or tape from the A/C lines.
  6. Install the new sealing washers onto the A/C line. Refer to Sealing Washer Replacement .
  7. Install the A/C lines to the auxiliary TXV.

    8. Object Number: 882519 Size: SH
  8. Install the auxiliary TXV line block fitting retaining bolt and tighten to 11 N·m (97 lb in) .

    9. Object Number: 882517 Size: SH
  9. Install the auxiliary TXV line clamp to the HVAC module assembly.
  10. Install the auxiliary TXV line clamp screw and tighten to 1.65 N·m (14 lb in) .
  11. Install a new foam wrap to the auxiliary TXV.
  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 detector .
  14. Install the left lower quarter trim panel. Refer to Rear Quarter Trim Panel Replacement - Left Side .