Operation CHARM: Car repair manuals for everyone.
Home >> Pontiac >> 2009 >> G3 L4-1.6L >> Repair and Diagnosis >> Heating and Air Conditioning >> Expansion Block/Orifice Tube >> Service and Repair
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

Or, hide this message: temporarily or permanently

Expansion Block/Orifice Tube: Service and Repair




Air Conditioning Evaporator Thermal Expansion Valve Replacement

Removal Procedure




Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Service and Repair).
3. Remove the liquid evaporator pipe connector block retaining nut at the cowl.




4. Remove the expansion valve connector block retaining bolts.
5. Remove the expansion valve.




6. Discard the O-rings.

Installation Procedure




1. Clean the O-ring surface areas of dirt or contamination.
2. Install new O-rings on the evaporator tubes.
3. Install a new expansion valve onto the evaporator tubes.

Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the expansion valve retaining bolts.

Tighten the expansion valve retaining bolts to 12 Nm (106 lb in).




5. Install the liquid evaporator pipe connecting block retaining nut at the cowl.

Tighten the liquid evaporator pipe connecting block retaining nut to 15 Nm (11 lb ft).

6. Connect the negative battery cable.
7. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging (Service and Repair).

pro multis · About Operation CHARM