Expansion Block/Orifice Tube: Service and Repair

TOOLS REQUIRED
J 26549-E Valve Core Remover/Installer The expansion (orifice) tube is located at the condenser to evaporator tube connection in the evaporator tube.

IMPORTANT: Past production vehicles may use orifice tubes with the following characteristics:
^ Different designs
^ Different colors

When you replace an orifice tube, compare the design of the orifice tube to the design of the replacement part for the correct selection. Different styles of orifice tubes are not interchangeable.

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the upper closeout panel.
3. Disconnect the connection at the condenser (3). Discard the O-ring seals.
4. Remove the evaporator line (4) from the clip (6) on the body side rail.

IMPORTANT: Use care when removing the expansion tube (7).

5. Use a J 26549-E or needle-nose pliers in order to remove the expansion tube (7).
6. Use the following procedure in order to remove a restricted or plugged expansion (orifice) tube (7).
6.1 Remove as much of any impacted residue as possible.
6.2. Use a heat gun in order to apply heat to the expansion (orifice) tube (7). Apply the heat approximately 7 mm (0.25 in) from the dimples on the inlet pipe.
6.3. While applying heat, use a J 26549-E in order to grip the expansion tube (7).
6.4. In order to loosen and remove the impacted expansion tube, using the following motions:
^ A turning motion
^ A push-pull motion

INSTALLATION PROCEDURE
1. Install the new expansion tube (7).
2. Install the evaporator line (4) to the clip (6).

NOTE: Refer to Fastener Notice in Service Precautions.

3. Connect the evaporator tube/condenser connection. Use the new O-ring seals.

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

4. Install the upper closeout panel.
5. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.