Tools Required

1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls-4.3L.
2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
3. Remove the evaporator tube from the evaporator.
4. Remove the O-ring seal.



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

6.1.	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.

6.2.	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. DO NOT overheat the pipe.

6.3.	While applying heat, use the J 26549-E in order to remove the orifice tube.

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

6.5.	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. Install the new O-ring seal. Refer to O-Ring Replacement .

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.

3. Install the evaporator tube to the evaporator.

Tighten
Tighten the evaporator tube nut to 28 N·m (20 lb ft).

4. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging .
5. Leak test the fittings of the component using the J 39400-A .
6. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls-4.3L.