Expansion Block/Orifice Tube: Service and Repair

Air Conditioning Evaporator Thermal Expansion Valve Tube Replacement

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant.
2. Remove the air cleaner assembly.
3. Remove the brake pressure modulator valve bracket (BPMV).




4. Remove the A/C line coupling from the evaporator tube to condenser tube.
5. Disconnect the evaporator tube from the condenser tube.
6. Remove the evaporator tube mounting bolt.
7. Remove the block fitting nut that secures the A/C compressor hose to the evaporator tube.
8. Disconnect the A/C compressor hose from the evaporator tube.




9. Remove the block fitting nut (1) that secures the evaporator tube to the thermostatic expansion valve (TXV).
10. Disconnect the evaporator tube from the TXV.
11. Remove the evaporator tube from the support clip on the left fender rail.
12. Disconnect the wire harness electrical connector from the A/C pressure sensor.
13. Remove the evaporator tube from the vehicle.




14. Remove the A/C pressure sensor.
15. Remove and discard the O-ring seals and seal washers.

Installation Procedure

1. Replace the O-ring seals on the evaporator tube and A/C pressure sensor.






Notice: Refer to Fastener Notice.

2. Install the A/C refrigerant pressure sensor.

Tighten the sensor to 4.7 N.m (41 lb in).

3. Replace the seal washers on the evaporator tube.
4. Install the evaporator tube to the vehicle.
5. Connect the evaporator tube to the support clip.
6. Install the evaporator tube to the TXV.




7. Install the evaporator tube to TXV nut (1).

Tighten the nut to 17 N.m (13 lb ft).

8. Connect the evaporator tube to the condenser tube.




9. Install the A/C line coupling to the evaporator tube and condenser tube.
10. Connect the A/C compressor hose assembly to the evaporator tube.
11. Install the A/C compressor hose assembly to evaporator tube block fitting nut.

Tighten the nut to 17 N.m (13 lb ft).

12. Install the brake pressure modulator valve bracket.
13. Install the master cylinder to the brake booster.
14. Install the nuts to the master cylinder.

Tighten the nuts to 25 N.m (18 lb ft).

15. Connect the electrical connector to the brake fluid level sensor.
16. Install the engine vacuum line to the brake booster.
17. Connect the electrical connector to the A/C refrigerant pressure sensor.
18. Install the air cleaner assembly.
19. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
20. Leak test the fittings of the component using J 39400-A.