For 1990-2009 cars

## Air Conditioning Evaporator Thermal Expansion Valve Replacement RHD

### Tools Required

J 39400 Halogen Leak Detector

### Removal Procedure

Caution: Refer to Safety Glasses Caution in the Preface section.

1. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
2. Remove the engine cover. Refer to Engine Cover Replacement for 3.6L engine, or Engine Cover Replacement for 6.0L engine.
3. Recover the refrigerant Refer to Refrigerant Recovery and Recharging.
4. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
5. Remove windscreen wiper arms. Refer to Windshield Wiper Arm Replacement.
6. Remove the air inlet grill panel. Refer to Air Inlet Grille Panel Replacement.
7. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement for 3.6L engine, or Air Cleaner Assembly Replacement for 6.0L engine.
8. Remove the exhaust manifold heat shield to air box retaining clips (2).
9. Remove the exhaust manifold heat shield (1).
10. Remove the insulation panel to air box retaining clips (2).
11. Remove the insulation panel (1) from the engine compartment.
12. Remove the remote battery positive post cover (1).
13. Remove the remote battery positive post to wiring harness retaining bolt (1).
14. Remove the starter motor power cable (2) and position aside.
15. Remove the suction pipe upper to suction pipe lower retaining nut (1).
16. Remove the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
17. Detach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).
18. Disconnect the suction pipe upper (1) from suction pipe lower (2).

Important: The sealing washer (3) is a single use item and must be discarded after use.

19. Remove the sealing washer (3). Refer to Sealing Washer Replacement .

Discard the sealing washer

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

20. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).
21. Remove the suction pipe/liquid pipe pad to thermal expansion (TX) valve retaining nut (1).
22. Disconnect the suction pipe/liquid pipe pad (3) from the TX valve (1).

Important: The sealing washers (2) are a single use item and must be discarded after use.

23. Remove the sealing washers (2). Refer to Sealing Washer Replacement .

Discard the sealing washers

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

24. Cap or plug the suction pipe (4), liquid pipe (5) and the TX valve (1).

Important: Using a suitable tool, unscrew the TX valve to evaporator pad retaining hex screws (1).

25. Remove the TX valve to evaporator pad retaining screws (1).

Important: Reinstall the suction pipe/liquid pipe to TX valve retaining nut to assist in the removal of the TX valve.

26. Reinstall the suction pipe/liquid pipe to TX valve retaining nut (2).

Important: Place the TX Valve in a plastic bag to avoid any contamination from air born dirt or moisture.

27. Remove the TX valve (3) from the evaporator pad (1).

Important: The sealing washers (2) are a single use item and must be discarded after use.

28. Remove the sealing washers (2) from the evaporator pad (1). Refer to Sealing Washer Replacement .

Discard the sealing washers

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

29. Cap or plug the suction pipe (4), liquid pipe (5) and the TX valve (1).

### Installation Procedure

1. Remove the plugs or caps from the thermal expansion (TX) valve (3) and the evaporator pad (1).

Important: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

2. Install NEW sealing washers (2) to the evaporator pad (1). Refer to Sealing Washer Replacement .
3. Connect the TX valve (3) to the evaporator pad (1).
4. Remove the plugs or caps from the suction pipe (4), liquid pipe (5) and the TX valve (1).

Important: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

5. Install NEW sealing washers (2). Refer to Sealing Washer Replacement .
6. Connect the suction pipe/liquid pipe pad (3) to the TX Valve (1).

Notice: Refer to Fastener Notice in the Preface section.

7. Install the suction pipe/liquid pipe pad to TX valve retaining nut (1).

Tighten
Tighten the nut to 22 N·m(16 lb ft).

8. Remove the plugs or caps from the suction pipe upper (1) and the suction pipe lower (2).

Important: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

9. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement .
10. Install the suction pipe upper (1) to the suction pipe lower (2).
11. Attach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).
12. Install the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
13. Install the suction pipe upper to suction pipe lower retaining nut (1).

Tighten
Tighten the nut to 22 N·m( 16 lb ft).

14. Install the starter motor positive cable (2) to the remote battery positive post.
15. Install the remote battery positive post to wiring harness retaining bolt (1).

Tighten
Tighten the bolt to 15 N·m (11 lb ft).

Important: Make sure the clips on the remote battery positive post cover (1) are engaged to avoid an induced rattle condition.

16. Install the remote battery positive post cover (1) to the remote battery positive post.
17. Install the insulation panel (1) to the left rear side engine compartment.
18. Install the insulation panel to air box retaining clips (2).
19. Install the exhaust manifold heat shield (1).
20. Install the exhaust manifold heat shield to air box retaining clips (2).
21. Attach the suction pipe (2) and the liquid pipe (3) from the suction pipe/liquid pipe retaining clip (1).
22. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
23. Install the radiator air baffle and deflector. . Refer to Radiator Air Upper Baffle and Deflector Replacement.
24. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement for 3.6L engine, or Air Cleaner Assembly Replacement for 6.0L engine.
25. Install the engine cover. Refer to Engine Cover Replacement for 3.6L engine, or Engine Cover Replacement for 6.0L engine.
26. Install the plenum chamber cover panel. Refer to Air Inlet Grille Panel Replacement.
27. Install the windscreen wiper arms. Refer to Windshield Wiper Arm Replacement.
28. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
29. Leak test the fittings of the component using J 39400 .