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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 242 (Heating, Ventilation And Air Conditioning - Gas) >> Repair Instructions >> Expansion (Orifice) Tube Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lightly coat the new orifice tube O-ring seal (4) with mineral base 525 viscosity refrigerant oil.
    Fig 1: Inspecting Expansion (Orifice) Tube
    GM296238Courtesy of GENERAL MOTORS CORP.
  2. Remove the cap or tape from the evaporator tube.
  3. Using needle-nose pliers, CAREFULLY grasp the edge of the expansion (orifice) tube (short filter screen (2) inlet side of tube) without touching the filter screen and insert the tube (long filter screen (1) outlet side first) fully into the evaporator line.
  4. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the tube fittings.
  5. Install a new O-ring seal on the condenser tube.

    Coat the O-ring seal with 525 viscosity refrigerant oil.

  6. Install the evaporator tube. Refer to Evaporator Tube Replacement .
    Fig 2: Exploded View Of Evaporator Tube
    GM599787Courtesy of GENERAL MOTORS CORP.
  7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  8. Leak test the fittings of the component using the J 39400-A  .
  9. Install the hood close out filler panel. Refer to Hood Close Out Filler Replacement in Body Front End.
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