Tools Required

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
2. Remove the evaporator tube from the evaporator (1). Refer to Evaporator Tube Replacement .
3. Remove the O-ring seal and discard.



4. Use the J 26549-E in order to remove the expansion (orifice) tube (2).
5. If you have difficulty removing a restricted or plugged expansion (orifice) tube, use the following procedure:

5.1.	Remove as much of any impacted residue as possible.

Notice: If the system has a pressure switch near the expansion (orifice) tube location, it should be removed prior to heating the pipe to avoid damage to switch.

Important: DO NOT overheat the pipe.

5.2.	Carefully apply heat with a heat gun (hair dryer, epoxy dryer, or equivalent) approximately 7 mm (0.25 in) from the dimples on the inlet pipe.

5.3.	While applying heat, use the J 26549-E or equivalent in order to grip the expansion (orifice) tube.

5.4.	Use a turning motion along with a push-pull motion in order to loosen the impacted expansion (orifice) tube.

Remove the expansion (orifice) tube.

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

1. Use the J 26549-E in order to install the expansion (orifice) tube (2).
2. Coat the new O-ring seal with 525 viscosity refrigerant oil.
3. Install the new O-ring seal.

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 to the evaporator (1).

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

5. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
6. Leak test the fittings components using the J 39400-A .