Malibu V6-3.1L VIN J (2002)
Expansion Block/Orifice Tube: Service and Repair
EXPANSION (ORIFICE) TUBE REPLACEMENT
TOOLS REQUIRED
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J 39400-A Halogen Leak Detector
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J 26549-E Orifice Tube Remover
REMOVAL PROCEDURE
IMPORTANT: 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.
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Raise the vehicle.
3. Remove the bolt holding the evaporator hose assembly to the condenser.
4. Remove the evaporator hose assembly from the condenser.
IMPORTANT: Immediately cap or tape the open end of the condenser line to prevent contamination.
5. Remove and discard the Seal washer.
6. Use J 26549-E to remove the orifice tube.
7. Use the following procedure in order to remove a restricted or plugged expansion (orifice) tube:
7.1.
Remove as much as possible of the impacted residue.
7.2.
Use a heat gun in order to apply heat to the expansion (orifice) tube. Apply the heat approximately 7 mm (1/4 in) from the dimples on the
inlet pipe.
7.3.
While applying heat, use pliers in order to grip the orifice tube. Use a turning motion along with a push-pull motion.
This will loosen the impacted orifice tube and remove the tube.
7.4.
Swab the inside of the evaporator inlet line to clean any contamination from the line.