GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Suzuki 🢒 2009 🢒 XL-7 FWD 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Evaporator Outlet Hose Replacement

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure

    Object Number: 1646736 Size: SH
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  2. Remove the evaporator outlet hose nut from the evaporator outlet hose.
  3. Remove the evaporator outlet hose from the compressor hose.

    4. Object Number: 1646735 Size: SH
  4. Remove the evaporator outlet hose and liquid line retainer plate nut from the thermal expansion valve (TXV).
  5. Remove the evaporator outlet hose and liquid line from the TXV.
  6. Remove evaporator outlet hose from the vehicle.
  7. Remove and discard the sealing washers from the evaporator outlet hose and the compressor hose. Refer to Sealing Washer Replacement.
  8. Install protective caps to the TXV, the liquid line, and the compressor hose to prevent contamination and desiccant saturation.

Installation Procedure

    Object Number: 1646735 Size: SH
  1. Remove the protective caps from the TXV, the liquid line, and the compressor hose.
  2. Install new sealing washers to the evaporator outlet hose, liquid line, and the compressor hose. Refer to Sealing Washer Replacement.
  3. Install the evaporator outlet hose and the liquid line to the TXV.

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

  4. Install the evaporator outlet hose and the liquid line nut to the TXV.

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


    Object Number: 1646736 Size: SH
  5. Install the evaporator outlet hose to the compressor hose.
  6. Install the evaporator outlet hose nut to the evaporator outlet hose.

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

  7. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
  8. Test the affected A/C joints for leaks using J 39400-A .