Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Remove the left wiper arm linkage nuts.

Reposition the left wiper arm linkage for access.

3. Reposition the heater hoses for clearance.
4. Disconnect the vacuum hose from the brake booster and reposition.



5. Remove the evaporator outlet tube to TXV nut.
6. Disconnect the evaporator outlet and inlet tubes from the TXV.
7. Disconnect the evaporator outlet tube from the evaporator tube line.
8. Remove and discard the sealing washers.

Important: Cap or tape the open evaporator inlet and outlet tubes immediately to prevent contamination of the refrigerant system.

9. Cap off the evaporator inlet and outlet tubes.



10. Remove the TXV to evaporator bolts.
11. Remove the TXV from the evaporator core.
12. Remove and discard the sealing washers.

1. Using a lint-free clean, dry cloth, carefully clean the sealing surface of the evaporator core and the TXV.

Important: Flat washer type seals do not require lubrication.

2. Carefully slide the new sealing washers onto the evaporator core until seated.



3. Install the TXV to the evaporator core.

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.

4. Install the TXV to evaporator bolts.

Tighten
Tighten the bolts to 3.2 N·m (28 lb in).

5. Remove the cap or tape from the evaporator inlet and outlet tubes.
6. Using a lint-free clean, dry cloth, carefully clean the sealing surface of the evaporator inlet and outlet tubes and the TXV.
7. Carefully slide the new sealing washers onto the evaporator inlet and outlet tubes until seated.
8. Install the evaporator inlet tube to the evaporator outlet tube.
9. Install the evaporator outlet and inlet tubes to the TXV.



10. Install the evaporator outlet tube nut.

Tighten
Tighten the nut to 16 N·m (12 lb ft).

11. Connect the vacuum hose to the brake booster.
12. Reposition the heater hoses.
13. Install the left wiper arm linkage.
14. Install the left wiper arm linkage nuts.

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

15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
16. Leak test the fittings of the component using J 39400-A .