GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Malibu 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Expansion (Orifice) Tube Replacement

Tools Required

    • J 39400-A Halogen Leak Detector
    • J 26549-E Orifice Tube Remover

Removal Procedure

Important: 

   • The expansion (orifice) tube is located at the condenser to evaporator hose connection in the evaporator hose.
   • When you replace an expansion (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.


    Object Number: 588303 Size: SH
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the bolt holding the evaporator hose assembly to the condenser.
  4. Remove the evaporator hose assembly from the condenser.

    5. Important: Cap or tape the open end of the condenser line immediately to prevent contamination.

  5. Remove and discard the O-ring seal.
  6. Remove the orifice tube using J 26549-E .

    7. Object Number: 296238 Size: SH
  7. Inspect the expansion (orifice) tube for the following conditions and clean or replace with a new tube as indicated:
    8. • Broken plastic frame; replace tube
    • Filter screen (1,2) torn, damaged or plugged with fine gritty material; replace tube
    • Brass orifice tube (3) damaged or plugged; replace tube
    • Filter screen (1) coated with metal chips, flakes, or slivers; coating may be removed with low pressure shop air and reused if cleaned satisfactorily
    • If reusing the tube, install a new O-ring (4).

Installation Procedure

    Object Number: 296238 Size: SH
  1. Lightly coat the new orifice tube O-ring seal (4) with mineral base 525 viscosity refrigerant oil.
  2. Remove the cap or tape from the evaporator line.
  3. Remove the cap or tape from the condenser line.
  4. Install the orfive tube usingJ 26549-E
  5. Using a lint-free, clean, dry, cloth, carefully clean the sealing surfaces of the line fittings.

    6. Object Number: 588303 Size: SH
  6. Install a NEW O-ring seal on the condenser tube.

    7. Coat the O-ring seal with 525 viscosity refrigerant oil.

    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.

  7. Install the evaporator hose assembly and the bolt to the condenser.

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

  8. Lower the vehicle.
  9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  10. Leak test the fittings of the component using the J 39400-A .