Expansion Block/Orifice Tube: Service and Repair

EVAPORATOR CORE ORIFICE

Special Tool(s):

SPECIAL TOOL(S)

REMOVAL

All vehicles
1. Recover the refrigerant.
2. Position the vehicle on a hoist with the gear selector in NEUTRAL.

Vehicles with I4 engine







3. Remove the heat shield.

All vehicles







4. Disconnect the evaporator core orifice connection.
- Discard the O-ring seal.







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 evaporator core orifice.







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

INSTALLATION

All vehicles







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. Connect the evaporator core orifice access fitting.
- Install a new O-ring seal lubricated in clean PAG oil.

Vehicles with I4 engine







5. Install the heat shield.

All vehicles
6. Evacuate, leak test and charge the refrigerant system.