Expansion (Orifice) Tube Replacement Front Only System

Tools Required

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the accumulator. Refer to Air Conditioning Accumulator Replacement .
3. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.



4. Remove the evaporator tube nut (3) at the evaporator (1).
5. Remove the evaporator tube (4) from the evaporator (1).



6. Remove the O-ring seal and discard.
7. Remove the nut from the evaporator tube block fitting.
8. Separate the evaporator tubes (4,6) at the block fitting.
9. Use the J 26549-E in order to remove the expansion tube.
10. Remove the expansion tube from the evaporator tube (6).

Important: Install the shorter screen end of the expansion tube into the evaporator tube (6) first.

1. Use the J 26549-E in order to install the expansion tube.
2. Install the new O-ring seal. Refer to O-Ring Replacement .
3. Assemble the evaporator tubes (4,6).

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.

4. Install the evaporator tube nut.

Tighten
Tighten the nut to 28 N·m (21 lb ft).




5. Connect the evaporator tube (4) to the evaporator (1).
6. Install the nut (3).

Tighten
Tighten the nut to 28 N·m (21 lb ft).

7. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
8. Install the accumulator. Refer to Air Conditioning Accumulator Replacement .
9. Recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
10. Leak test the fittings of the components using the J 39400-A .

Expansion (Orifice) Tube Replacement Auxiliary System

Tools Required

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the accumulator. Refer to Air Conditioning Accumulator Replacement .
3. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.



4. Loosen the evaporator tube nut (5) from the evaporator.
5. Remove the evaporator tube from the evaporator.



6. Remove the nut (2) from the evaporator tube block (3).
7. Separate the evaporator tube at the block fitting (3).
8. Use the J 26549-E in order to remove the expansion tube (4).
9. Remove the O-ring seal and discard.
10. Remove the expansion tube (4) from the evaporator tube (1).

Important: Install the shorter screen end of the expansion tube into the evaporator tube first.

1. Install the expansion tube (4) to the evaporator tube (1).
2. Use the J 26549-E in order to install the expansion tube (4).
3. Install the new O-ring seal. Refer to O-Ring Replacement .
4. Assemble the evaporator tube at the block fitting (3).
5. Install the nut (2) to the evaporator tube block (3).

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.

6. Install the evaporator tube nut.

Tighten
Tighten the nut to 28 N·m (21 lb ft).




7. Install the evaporator tube to the evaporator.
8. Install the evaporator tube nut (5) to the evaporator.

Tighten
Tighten the nut to 28 N·m (21 lb ft).

9. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
10. Install the accumulator. Refer to Air Conditioning Accumulator Replacement .
11. Recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
12. Leak test the fittings of the components using the J 39400-A .