GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1998 🢒 Grand Prix 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Expansion (Orifice) Tube Replacement

Removal Procedure
  1. Remove the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L or Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  3. Remove the EBTCM. Refer to Electronic Brake and Traction Control Module Replacement in Antilock Brake System.

    4. Object Number: 82109 Size: SH

    Important: If the expansion (orifice) tube is restricted or plugged, perform the following procedure:

  4. Remove the expansion (orifice) tube.
  5. Remove the impacted residues.
  6. Using a heat gun (hair dryer, epoxy dryer or the equivalent), apply heat approximately ¼  inch from the dimples on the inlet pipe. Do not overheat the pipe.
  7. While applying heat, perform the following steps:
    8. 7.1. Use needle-nose pliers in order to grip the orifice tube.
    7.2. Use a turning motion along with a push-pull motion in order to loosen the impacted orifice tube.
    7.3. Remove the orifice tube.
  8. Add 30 ml (1 oz) of Polyalkylene Glycol (PAG) Synthetic Refrigerant Oil to the system.
  9. Lubricate the new expansion (orifice) tube and O-ring seal with mineral base 525 viscosity refrigerant oil and insert into the inlet pipe.
  10. Install tube with the smaller screen (3) first.
  11. Remove the O-rings seals (2).

Installation Procedure

    Object Number: 82109 Size: SH

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

  1. Install the new O-ring seals (2).

    2. Install the new expansion (orifice) tube with the shorter screen (3) end in first.

  2. Install the liquid line/suction line bracket.
  3. Connect the electrical connector to the A/C refrigerant pressure sensor.
  4. Install the EBTCM. Refer to Electronic Brake and Traction Control Module Replacement in Antilock Brake System.
  5. Evacuate and charge the system. Refer to Refrigerant Recovery and Recharging .
  6. Inspect the system for leaks. Refer to Leak Testing .
  7. Install the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L or Air Cleaner Assembly Replacement in Engine Controls - 3.8L.