Expansion (Orifice) Tube Replacement for Chevrolet Monte Carlo 2002

Tools Required

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.4L or Air Cleaner Assembly Replacement in Engine Controls -3.8L.
3. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
4. Remove the condenser tube. Refer to Condenser Tube Replacement .
5. Use J 26549-E in order to remove the expansion orifice tube.




Important: DO NOT use any solvents or chemicals to clean the porous plastic inlet filter of the expansion orifice tube.

6. Inspect the expansion orifice tube for the following conditions and clean or replace with a new tube as indicated:

•	Broken plastic frame (1); replace the tube.

•	Inlet filter (3) damaged or plugged with fine gritty material; replace the tube.

•	Inlet filter (3) coated with metal chips, flakes, or slivers; remove the coating with low pressure shop air ONLY and reuse if the filter is cleaned satisfactorily. Do NOT reuse the O-ring seals (2).

Important: Lubricate the new O-ring seals (2) with mineral base 525 viscosity refrigerant oil.

1. If you reuse the orifice tube, install new O-ring seals (2).
2. Carefully grasp the edge of the expansion orifice tube (1) without touching the inlet filter (3) and insert the expansion tube into the condenser tube until fully seated.
3. Install the condenser tube. Refer to Condenser Tube Replacement .
4. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.4L or Air Cleaner Assembly Replacement in Engine Controls -3.8L.
6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
7. Leak test the fittings of the component using J 39400-A .