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 air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
3. If equipped, remove the windshield washer solvent heater. Refer to Windshield Washer Solvent Heater Replacement.
4. Remove the evaporator thermal expansion valve (TXV) tube from the TXV.
5. Remove and discard the seal washers.
6. Remove the TXV bolts.
7. Remove the TXV.
8. Remove and discard the seal washers.

### Installation Procedure

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

Caution: Refer to Fastener Caution in the Preface section.

3. Install the TXV bolts. Insert a small phillips screwdriver through one of the TXV bolt holes and into the threaded hole of the mounting plate. Install the TXV bolt into the other hole without the screwdriver. Remove the screwdriver and install the other TXV bolt.

Tighten
Tighten the bolts to 5 N·m (44 lb in).

4. Install new sealing washers on the evaporator TXV tube 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. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
8. If removed, install the windshield washer solvent heater. Refer to Windshield Washer Solvent Heater Replacement.
9. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
10. Leak test the fittings using the J 39400-A .