Expansion Valve: Service and Repair

Thermal Expansion Valve Replacement

Tools Required

J39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
2. Reposition the heater hoses for clearance.
3. Disconnect the vacuum hose from the brake booster and reposition.




4. Remove the evaporator outlet tube to thermal expansion valve (TXV) nut.
5. Disconnect the evaporator outlet tube from the TXV.
6. Disconnect the evaporator outlet tube from the evaporator inlet tube.
7. Remove and discard the sealing washers.

Important: Cap or tape the open A/C refrigerant tubes immediately to prevent contamination of the refrigerant system.

8. Cap or tape off the A/C refrigerant tubes.




9. Remove the TXV to evaporator bolts.
10. Remove the TXV from the evaporator core.
11. Remove and discard the sealing washers.
12. Cap or tape off the evaporator core.

Installation Procedure

1. Remove the cap or tape from the evaporator core.
2. Install the new sealing washers onto the evaporator core.




3. Install the TXV to the evaporator core.

Notice: Refer to Fastener Notice.

4. Install the TXV to evaporator bolts.

Tighten the bolts to 3.2 N.m (28 lb in).

5. Remove the cap or tape from the A/C refrigerant tubes.
6. Install the sealing washers onto the A/C refrigerant tubes.
7. Install the evaporator inlet tube to the evaporator outlet tube.
8. Install the evaporator outlet and inlet tubes to the TXV.




9. Install the evaporator outlet tube nut.

Tighten the nut to 16 N.m (12 lb ft).

10. Connect the vacuum hose to the brake booster.
11. Reposition the heater hoses.
12. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
13. Leak test the fittings of the component using J39400-A.