Expansion Block/Orifice Tube: Service and Repair

WARNING: Before for working on air-conditioning system, Service Precautions

NOTE:
- Read notes on slow and fast leaks in " General Repair Instructions." Service and Repair
- When replacing refrigerant pipes/hoses or replacing/cleaning fluid and expansion pipes, remove the refrigerant pipe between the evaporator and receiver/dryer first. Details of how to replace all pipes and hoses are given below: use appropriate parts.
- When changing pipes/hoses, always change 0-rings and snap-on connections as well.
- Special tools: 5385, 5472

Removal





1. Disconnect battery negative cable.
2. Drain system of refrigerant. Service and Repair
3. Lift expansion chamber
- Disconnect connector beneath chamber.
- Lift and put chamber on engine.
4. Disconnect Pressostat connector. (Q4)
5. Disconnect control unit box air Intake hoses. (Q5)
- Remove right-hand headlight cover.
6. Remove refrigerant pipe from between evaporator and receiver/dryer. (Q6)
- Disconnect holding screw on receiver/dryer bracket (to increase play).
- Disconnect snap-on couplings at both ends of pipe, using removal tool 5472.
- Plug snap-on connectors to receiver/dryer.
- Switch Pressostat to new pipe. Torque setting 3 Nm (2 ft.lb.).





7. Remove fluid pipe. (Q7)
- Disconnect pipe connection to condenser.
- Disconnect snap-on couplings from center board, using removal tool 5385.
8. Mark position of pipes relative to one another.
- Separate flange connection and replace/clean out expansion pipe.
- Expansion pipe can be removed using pointed pliers.
- Replace pipes if necessary.

Installation:

NOTE: Use new 0-rings lubricated with compressor oil in all pipes and snap-on connections.

- Expansion pipe, torque setting 30 Nm (22 ft.lb.).

NOTE: Observe marking when tightening flange.

- Fluid pipe, connection to compressor: torque setting 20 Nm (15 ft.lb.).
- Refrigerant pipe between evaporator and receiver/dryer, remove plug to dryer bottle first.
- Pressostat connector.
- Expansion chamber connector.
- Control unit box air intake hoses.
- Battery negative cable.
- Fill system with refrigerant and test for leaks. Service and Repair