For 1990-2009 cars

### Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the A/C line block fitting bolt.

Important: Cap or tape the open A/C refrigerant lines immediately.

4. Separate the line block fitting, remove and discard the O-ring seal, and cap or tape the A/C line to prevent contamination of the refrigerant system.
5. Lower the vehicle.
6. Remove the left side rear quarter trim. Refer to Rear Quarter Lower Trim Panel Replacement in Interior Trim.
7. Remove the nut from the line block fitting at the thermal expansion valve.
8. Carefully remove the A/C lines from the thermal expansion valve and pull the lines up through the floor of the vehicle.

Important: Cap or tape the open A/C refrigerant lines immediately.

9. Remove and discard the O-ring seals and cap or tape the lines to prevent contamination.
10. Remove the bolts from the thermal expansion valve that were exposed by removal of the line block fitting.
11. Remove the thermal expansion valve from the evaporator core lines.

Important: Cap or tape the open A/C refrigerant lines immediately.

12. Remove and discard the O-ring seals from the evaporation core lines. Cap or tape the lines to prevent contamination of the evaporator core.

### Installation Procedure

1. Remove the cap or tape from the evaporator lines.
2. Using a lint-free clean, dry cloth, carefully clean the sealing surface of the evaporator lines and the thermal expansion valve.
3. Lightly coat the new O-ring seal (1) with mineral base 525 viscosity refrigerant oil.

Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system.

4. Carefully slide the new O-ring seal (1) onto the A/C line until seated.

Allow a light coating of the refrigerant oil to remain on the A/C line in the area indicated (2) ONLY.

5. Install the thermal expansion valve onto the evaporator core lines.

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.

6. Install the bolts through the thermal expansion valve to the A/C line block fitting on the evaporator core lines.

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

7. Remove the cap or tape from the A/C lines.
8. Using a lint-free clean, dry cloth, carefully clean the sealing surface of the A/C lines and the thermal expansion valve.
9. Lightly coat the new O-ring seal (1) with mineral base 525 viscosity refrigerant oil.

Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system.

10. Carefully slide the new O-ring seal (1) onto the A/C line until seated.

Allow a light coating of the refrigerant oil to remain on the A/C line in the area indicated (2) ONLY.

11. Carefully install the A/C lines through the floor of the vehicle and then up to the thermal expansion valve.

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.

12. Install the retaining nut to the line block fitting on the A/C lines

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

13. Install the left rear quarter trim. Refer to Rear Quarter Lower Trim Panel Replacement in Interior Trim.
14. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
15. Remove the cap or tape from the A/C lines.
16. Using a lint-free clean, dry cloth, carefully clean the sealing surface of the evaporator lines and the thermal expansion valve.
17. Lightly coat the new O-ring seal (1) with mineral base 525 viscosity refrigerant oil.

Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system.

18. Carefully slide the new O-ring seal (1) onto the A/C line until seated.

Allow a light coating of the refrigerant oil to remain on the A/C line in the area indicated (2) ONLY.

19. Install the A/C line block fitting.

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.

20. Install the A/C line block fitting bolt.

Tighten
Tighten the bolt to 20 N·m ( 15 lb ft).

21. Lower the vehicle.
22. Evacuate, charge and leak test the system. Refer to Refrigerant Recovery and Recharging .