Expansion Block/Orifice Tube: Service and Repair

REMOVAL PROCEDURE




1. Remove the air cleaner and duct assembly.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging under Refrigerant, A/C Service and Repair.
3. Disconnect the ABS modulator electrical connector.
4. Disconnect the electrical connector from the A/C pressure sensor switch.
5. Remove the liquid/suction line bolt and bracket.




6. Remove the liquid line nut (1) at the orifice.




7. Remove the expansion (orifice) tube:
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.

IMPORTANT: DO NOT use any solvents or chemicals to clean the expansion (orifice) tube porous plastic inlet filter.

8. Inspect the expansion (orifice) tube for the following conditions and clean or replace with a new tube as indicated:
^ Broken plastic frame (1); replace tube.
^ Inlet filter (3) damaged or plugged with fine gritty material; replace tube.
^ Inlet filter (3) coated with metal chips, flakes, or slivers; coating may be removed with low pressure shop air ONLY and reused if cleaned satisfactorily.
^ If reusing the tube, discard the O-ring seals (2).

INSTALLATION PROCEDURE





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

1. Install the new O-ring seals (2), if reusing the orifice tube.
2. CAREFULLY grasp the edge of the expansion (orifice) tube (1) without touching the inlet filter (porous plastic) (3) and insert into the condenser tube until fully seated.





NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the liquid line nut (1) at the orifice.

Tighten
Tighten the liquid line nut to 27 N.m (20 lb ft).




4. Install the liquid/suction line bracket and bolt.

Tighten
Tighten the liquid/suction line bracket bolt to 6 N.m (54 lb ft).

5. Connect the electrical connector from the A/C pressure sensor switch.
6. Connect the ABS modulator electrical connector.
7. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging under Refrigerant, A/C Service and Repair.
8. Test the system for leaks. Refer to Leak Testing. Testing and Inspection
9. Install the air cleaner and duct assembly.