Air Conditioning Evaporator Hose Assembly Replacement 2.2L (L61), 2.4L (LE5)

Tools Required

J 39400-A Halogen Leak Detector

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



2. Remove the compressor hose from the evaporator hose.
3. Remove and discard the seal washer.



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

1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to Sealing Washer Replacement .
2. Install the condenser tube and evaporator hose to the TXV.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the TXV nut.

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




4. Install new seal washer to the compressor hose. Refer to Sealing Washer Replacement .
5. Install the compressor hose and nut to the evaporator hose.

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

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

Air Conditioning Evaporator Hose Assembly Replacement 2.0L (LSJ)

Tools Required

J 39400-A Halogen Leak Detector

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



2. Remove the compressor hose from the evaporator hose.
3. Remove and discard the seal washer.



4. Remove the retainer clamp from the evaporator hose.




Important: You may have to position the wires aside to remove the evaporator hose.

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

1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to Sealing Washer Replacement .
2. Install the condenser tube and evaporator hose to the TXV.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the TXV nut.

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




4. Install the new seal washer to the compressor hose. Refer to Sealing Washer Replacement .
5. Install the compressor hose and nut to the evaporator hose.

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




6. Install the retainer clamp to the evaporator hose.
7. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
8. Leak test the fittings using the J 39400-A .