GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 L300/LW300 🢒 Engine 🢒 Engine Electrical 🢒 Air Conditioning Evaporator Thermal Expansion Valve Replacement

Tools Required

    • J 44655 TXV Installation Tool
    • J 39400-A Halogen Leak Detector
    • J 43600 ACR 2000 Air Conditioning Service Center

Removal Procedure

    Object Number: 892746 Size: SH

    Caution: Do not remove hoses or lines before system is fully discharged. System may be under pressure and contact with R134a may cause personal injury.

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the nut that secures the evaporator hose assembly to the TXV.
  3. Remove the evaporator hose assembly from the TXV.
  4. Install a cap on the evaporator hose assembly to prevent oil spillage.

    5. Object Number: 893650 Size: SH
  5. Remove the TXV retaining bolts.

    6. Object Number: 893656 Size: SH
  6. Remove the TXV from the evaporator.

    7. Object Number: 893701 Size: SH
  7. Using your fingers or a plastic tool, remove the O-rings from the evaporator pipes. Use a mirror to view the O-rings on the evaporator core.

Installation Procedure

    Object Number: 894049 Size: SH
  1. Install new O-rings to the evaporator pipes. Refer to O-Ring Replacement .

    2. Object Number: 894735 Size: SH
  2. Install the TXV using J 44655 to support the evaporator pipes and mounting flange while installing the TXV.
    3. 2.1. Orient the TXV with the dome-shaped end toward the passenger side of the vehicle
    2.2. Install the cap screws through the T-handle and through the TXV
    2.3. Thread the 2 cap screws into the evaporative core flange
    2.4. Pull the T-handle back against the cap screws and carefully install and seat the TXV into position
    2.5. Carefully remove cap screws and T-handle

    Object Number: 893650 Size: SH
  3. Ensure that the TXV is completely installed. The TXV should be almost flush with the edge of the bevel of the foam seal.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 894741 Size: SH

    Notice: Improper installation of TXV to evaporator pipes will damage pipes and require evaporator core replacement.

    Important: The bolts should thread in easily. Do NOT use force. If the bolts do not thread in easily, verify that the TXV is properly installed onto both pipes and fully seated to the block.

  4. Thread by hand the bolts that secure the TXV to the evaporator core block.

    5. Tighten
    Tighten the bolts to 7 N·m (62 lb in).


    Object Number: 892746 Size: SH
  5. Install new O-rings to the evaporator hose assembly block. Refer to O-Ring Replacement .
  6. Install the evaporator hose assembly block to the TXV.
  7. Install the nut that secures the evaporator hose assembly to TXV.

    8. Tighten
    Tighten the nut to 7 N·m (62 lb in).

  8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  9. Using J 39400-A , leak test the fittings of the component.