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Home >> Chevrolet >> 2002 >> Astro Van Passenger, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 802 (Heating, Ventilation And Air Conditioning) >> Repair Instructions >> Expansion (Orifice) Tube Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Safari and 2003 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the air cleaner. Refer to AIR CLEANER ASSEMBLY in Removal & Installation.
  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.
    Fig 1: Removing Expansion (Orifice) Tube
    G01645577Courtesy of GENERAL MOTORS CORP.
  6. If you have difficulty removing a restricted or plugged expansion (orifice) tube, use the following procedure:
    1. 6.1. Remove as much of any impacted residue as possible.
      NOTE: 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.
    2. 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.
    3. 6.3. While applying heat, use the J 26549-E  in order to remove the orifice tube.
    4. 6.4. Use a turning motion along with a push-pull motion in order to loosen the impacted expansion (orifice) tube.
    5. 6.5. Remove the expansion (orifice) tube.
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