For 1990-2009 cars

The expansion (orifice) tube is located at the condenser to evaporator tube connection in the evaporator tube.

Important: In past production vehicles, the orifice tubes with following characteristics may have been used:

• | 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. The different styles of orifice tubes are not interchangeable.

### Removal Procedure

#### Tools Required

• | J 39500-B R-134a Refrigerant Recovery, Recycling and Recharging (ACR4) System

• | J 26549-E Valve Core Remover/Installer

1. Use the J 39500-B in order to recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Disconnect the connection at the condenser .

Discard the O-ring seals.

4. Remove the evaporator tube from the condenser.

Important: Use care when removing the expansion tube .

5. Use a J 26549-E or needle-nose pliers in order to remove the expansion tube (5).

Use the following procedure in order to remove a restricted or plugged expansion (orifice) tube (5):

5.1. | Remove as much of any impacted residue as possible.

5.2. | Use a heat gun in order to apply heat to the expansion (orifice) tube . Apply the heat approximately 7 mm (0.25 in) from the dimples on the inlet pipe.

5.3. | While applying heat, use a J 26549-E in order to grip the expansion tube .

5.4. | 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 .
2. Install the evaporator tube to the condenser.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: Use new O-ring seals.

3. Assemble the evaporator tube/condenser connection.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

4. Lower the vehicle.
5. Use the J 39500-B in order to evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .