For 1990-2009 cars

#### Special Tools

J 39400-A Halogen Leak Detector

### Removal Procedure

1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
3. Remove the compressor hose nut (1) from the evaporator hose.
4. Remove and discard the seal washer.
5. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
6. Remove and discard the seal washers.

### Installation Procedure

1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to Sealing Washer Replacement.
2. Install the condenser tube and evaporator hose to the TXV.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the TXV nut.

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

4. Install new seal washer to the compressor hose. Refer to Sealing Washer Replacement.
5. Install the compressor hose and nut (1) to the evaporator hose.

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

6. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement
7. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
8. Leak test the fittings using the J 39400-A .