Expansion Block/Orifice Tube: Service and Repair

SPECIAL TOOL(S)

REMOVAL

All vehicles
1. Prepare the vehicle for evaporator core orifice removal.
1 Disconnect the battery ground cable.
2 Recover the refrigerant.
3 Remove the air cleaner assembly.







2. Detach the speed control servo.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Position the speed control servo aside.







3. Position the coolant expansion tank/windshield washer reservoir aside.
1 Remove the screws and the nuts.
2 Position the coolant expansion tank/windshield washer reservoir aside.







4. Disconnect the condenser to evaporator tube spring lock coupling.







5. Inspect the evaporator core orifice for damage.

Vehicles with a serviceable evaporator core orifice







6. Engage the special tool with the evaporator core orifice.







7. Holding the special tool T-handle stationary, rotate the special tool body to remove the evaporator core orifice.

Vehicles with a damaged or broken evaporator core orifice







8. Screw the end of the special tool into the broken evaporator core orifice.







9. Holding the special tool T-handle stationary, rotate the special tool body to remove the broken evaporator core orifice.

INSTALLATION







1. Install new O-ring seals on the evaporator core orifice.
- Lubricate the new O-ring seals with PAG oil or equivalent.







2. Position the evaporator core orifice in the special tool.







3. Using the special tool, install the evaporator core orifice.







4. Install the coolant expansion tank/windshield washer reservoir.
1 Install the coolant expansion tank/windshield washer reservoir aside.
2 Install the screws and the nuts.







5. Install the speed control servo.
1 Install the speed control servo.
2 Install the bolt.
3 Connect the electrical connector.

6. Restore the vehicle to operating condition.
1 Install the air cleaner assembly.
2 Connect the battery ground cable.
3 Evacuate, leak test, and charge the A/C system.