For 1990-2009 cars

#### Special Tools

J 39400-A Halogen Leak Detector

### Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the evaporator outlet hose nut from the evaporator outlet hose.
3. Remove the evaporator outlet hose from the compressor hose.
4. Remove the evaporator outlet hose and liquid line retainer plate nut from the thermal expansion valve (TXV).
5. Remove the evaporator outlet hose and liquid line from the TXV.
6. Remove evaporator outlet hose from the vehicle.
7. Remove and discard the sealing washers from the evaporator outlet hose and the compressor hose. Refer to Sealing Washer Replacement .
8. Install protective caps to the TXV, the liquid line, and the compressor hose to prevent contamination and desiccant saturation.

### Installation Procedure

1. Remove the protective caps from the TXV, the liquid line, and the compressor hose.
2. Install new sealing washers to the evaporator outlet hose, liquid line, and the compressor hose. Refer to Sealing Washer Replacement .
3. Install the evaporator outlet hose and the liquid line to the TXV.

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.

4. Install the evaporator outlet hose and the liquid line nut to the TXV.

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

5. Install the evaporator outlet hose to the compressor hose.
6. Install the evaporator outlet hose nut to the evaporator outlet hose.

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

7. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
8. Test the affected A/C joints for leaks using J 39400-A .