Expansion Block/Orifice Tube: Service and Repair

Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
2. Remove the left lower quarter trim panel. Refer to Rear Quarter Trim Panel Replacement - Left Side (Service and Repair).
3. Remove the foam wrap from the auxiliary thermal expansion valve (TXV).




4. Remove the auxiliary TXV line clamp screws.
5. Remove the auxiliary TXV line clamp from the HVAC module assembly.




6. Remove the bolt from the auxiliary TXV line block fitting.
7. Remove the A/C lines from the auxiliary TXV.
8. Remove and discard the sealing washers.

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


9. Cap or tape the A/C lines.




10. Remove the auxiliary TXV to evaporator core bolts.
11. Remove the auxiliary TXV from the evaporator core.
12. Cap or tape off the evaporator core lines.
13. Remove and discard the sealing washers.

Installation Procedure

1. Remove the cap or tape from the evaporator lines.
2. Install the new sealing washers onto the evaporator lines. Refer to Sealing Washer Replacement (Sealing Washer Replacement).




3. Install the auxiliary TXV to the evaporator core.

Notice: Refer to Fastener Notice (Fastener Notice).

4. Install the auxiliary TXV to the evaporator core mounting bolts.

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

5. Remove the cap or tape from the A/C lines.
6. Install the new sealing washers onto the A/C line. Refer to Sealing Washer Replacement (Sealing Washer Replacement).
7. Install the A/C lines to the auxiliary TXV.




8. Install the auxiliary TXV line block fitting retaining bolt.

Tighten the nut to 11 N.m (97 lb in).




9. Install the auxiliary TXV line clamp to the HVAC module assembly.
10. Install the auxiliary TXV line clamp screw.

Tighten the screw to 1.6 N.m (14 lb in).

11. Install a new foam wrap to the auxiliary TXV.
12. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
13. Leak test the fittings of the component usingJ 39400-A.
14. Install the left lower quarter trim panel. Refer to Rear Quarter Trim Panel Replacement - Left Side (Service and Repair).