For 1990-2009 cars

#### Special Tools

J 39400-A Halogen Leak Detector

### Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the instrument panel (I/P) carrier. Refer to Refrigerant Recovery and Recharging .
3. Remove the insulation (1) from the thermal expansion valve (TXV). Discard the used insulation.
4. Remove the HVAC line clamp screw.
5. Remove the HVAC line clamp.
6. Remove the bolts (1) that secure the TXV to the evaporator.
7. Remove the TXV line bracket.
8. Remove the TXV from the evaporator core.

Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.

9. Straightly pull the TXV out from the A/C lines.
10. Remove the thermal expansion valve.
11. Remove and discard the O-ring seals. Refer to O-Ring Replacement .

### Installation Procedure

1. Lubricate the O-rings. Refer to O-Ring Replacement .
2. Install the A/C lines into the TXV.
3. Carefully slide the TXV onto the evaporator core until seated.
4. Install the TXV line bracket.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the bolts (1) that secure the TXV to the evaporator.

Tighten
Tighten the bolt to 3.5 N·m (31 lb in).

6. Install the HVAC line clamp.
7. Install the HVAC line clamp screw.

Tighten
Tighten the screw to 1 N·m (9 lb in).

8. Install new insulation (1) onto the lines and TXV.
9. Install the instrument panel carrier. Refer to Refrigerant Recovery and Recharging .
10. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .