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1 Expansion Block/Orifice Tube Service and Repair, Removal and Repla of 3 5/4/ :44 AM Air Conditioning Evaporator Thermal Expansion Valve Replacement Special Tools J A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging ( See: Heating and Air Conditioning > Procedures > Refrigerant Recovery and Recharging). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement ( See: Air Cleaner Fresh Air Duct/Hose > Removal and Replacement > Air Cleaner Outlet Duct Replacement). 3. If equipped, remove the windshield washer solvent heater. Refer to Windshield Washer Solvent Heater Replacement See: Washer Fluid Heater > Removal and Replacement > Windshield Washer Solvent Heater Replacement. 4. Remove the evaporator thermal expansion valve (TXV) tube from the TXV. 5. Remove and discard the seal washers.

2 Expansion Block/Orifice Tube Service and Repair, Removal and Repla of 3 5/4/ :44 AM 6. Remove the TXV bolts. 7. Remove the TXV. 8. Remove and discard the seal washers. Installation Procedure 1. Install the TXV seal strip. The center of the seal strip should cover the dome at the top of the TXV and then down both sides of the TXV. 2. Install new seal washers to the evaporator core fittings. Refer to Air Conditioning System Seal Replacement ( See: A/C Coupler O-ring > Removal and Replacement > Air Conditioning System Seal Replacement). 3. Install the TXV.

3 Expansion Block/Orifice Tube Service and Repair, Removal and Repla of 3 5/4/ :44 AM Caution: Refer to Fastener Caution ( See: Vehicle > Vehicle Damage Warnings > Fastener Caution). 4. Install the TXV bolts. Insert a small phillips screwdriver through one of the TXV bolt holes and into the threaded hole of the mounting plate. Install the TXV bolt into the other hole without the screwdriver. Remove the screwdriver and install the other TXV bolt. Tighten the bolts to 5 Nm (44 lb in). 5. Install new sealing washers on the evaporator TXV tube fittings. Refer to Air Conditioning System Seal Replacement ( See: A/C Coupler O-ring > Removal and Replacement > Air Conditioning System Seal Replacement). 6. Install the condenser tube and evaporator hose to the TXV. 7. Install the TXV nut. Tighten the nut to 20 Nm (15 lb ft). 8. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging ( See: Heating and Air Conditioning > Procedures > Refrigerant Recovery and Recharging). 9. If removed, install the windshield washer solvent heater. Refer to Windshield Washer Solvent Heater Replacement See: Washer Fluid Heater > Removal and Replacement > Windshield Washer Solvent Heater Replacement. 10. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement ( See: Air Cleaner Fresh Air Duct/Hose > Removal and Replacement > Air Cleaner Outlet Duct Replacement). 11. Leak test the fittings using the J A ALLDATA, LLC. All Rights Reserved. (Version )

4 Air Cleaner Fresh Air Duct/Hose Service and Repair, Removal and Repl of 3 5/4/ :44 AM Air Cleaner Outlet Duct Replacement Removal Procedure 1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement ( See: Fuel Injector > Removal and Replacement > Fuel Injector Sight Shield Replacement). 2. Disconnect the PCV quick disconnect (2). Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Line Coupler > Removal and Replacement > Plastic Collar Quick Connect Fitting Service).

5 Air Cleaner Fresh Air Duct/Hose Service and Repair, Removal and Repl of 3 5/4/ :44 AM 3. Loosen the air cleaner outlet duct clamps (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor and throttle body. 4. Remove the air cleaner outlet duct. Installation Procedure 1. Loosely Install the air cleaner outlet duct then install the fuel injector sight shield to ensure proper clearance. 2. Remove the fuel injector sight shield. Caution: Refer to Fastener Caution ( See: Vehicle > Vehicle Damage Warnings > Fastener Caution). 3. Tighten the air cleaner outlet duct clamps (1) to 4 Nm (35 lb in) at the MAF/IAT sensor and throttle body.

6 Air Cleaner Fresh Air Duct/Hose Service and Repair, Removal and Repl of 3 5/4/ :44 AM 4. Connect the PCV quick disconnect (2). Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Line Coupler > Removal and Replacement > Plastic Collar Quick Connect Fitting Service). 5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement ( See: Fuel Injector > Removal and Replacement > Fuel Injector Sight Shield Replacement) ALLDATA, LLC. All Rights Reserved. (Version )

7 Fuel Injector Service and Repair, Removal and Replacement: Fuel Inject of 1 5/4/ :45 AM Fuel Injector Sight Shield Replacement 2016 ALLDATA, LLC. All Rights Reserved. (Version )

8 Washer Fluid Heater Service and Repair, Removal and Replacement: W of 1 5/4/ :46 AM Windshield Washer Solvent Heater Replacement 2016 ALLDATA, LLC. All Rights Reserved. (Version )