Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSPONTIAC2004AZTEK AWD V6-3.4L VIN EREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGEXPANSION VALVESERVICE AND REPAIR
2004 Pontiac Aztek AWD V6-3.4L VIN E
Expansion Valve: Service and Repair
2004 Pontiac Aztek AWD V6-3.4L VIN ESECTION Service and Repair
THERMAL EXPANSION VALVE REPLACEMENT
TOOLS REQUIRED
J 39400-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 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.
NOTE: Refer to Fastener Notice in Service Precautions.
4. Install the TXV to evaporator bolts.
Tighten
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
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 J 39400-A.
TOOLS REQUIRED
J 39400-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 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.
NOTE: Refer to Fastener Notice in Service Precautions.
4. Install the TXV to evaporator bolts.
Tighten
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
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 J 39400-A.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.