OEM 2002 Chevrolet Malibu A/C Orifice Tube

2002 Chevrolet Malibu A/C Orifice Tube Parts and Q&A

• Q: How to replace the A/C Orifice Tube on 2002 Chevrolet Malibu?

  A: The necessary replacement tools for the expansion (A/C Orifice Tube) consist of the Halogen Leak Detector (J 39400-A) together with the A/C Orifice Tube Remover (J 26549-E). The first step requires recovery of refrigerant and vehicle lift. The first step involves removing the bolt that connects the evaporator hose assembly to the condenser before detaching the assembly while using tape to seal the condenser line opening against contaminant entry. The process requires discarding the seal washer before extracting the A/C orifice tube with A/C Orifice Tube Remover (J 26549-E). The presence of restrictions or plugging requires residue removal and heat application from a heat gun at 7 mm distance (1/4 in) from the inlet pipe dimples followed by plier use to extract the A/C orifice tube through push-pull movements for loosening. Clean the inside of the evaporator inlet line for removing any source of contamination. The expansion A/C orifice tube needs to be inspected for damage and a replacement should be conducted in case of issues. A new O-ring must be installed after applying mineral base 525 viscosity refrigerant oil to the surface lightly. The A/C orifice tube needs to be inserted into the evaporator line so start from the short filter screen outlet side before cleaning all line fitting sealing surfaces using a lint-free cloth. After installing a new seal washer to the condenser tube you can connect the evaporator hose assembly to the condenser as you tighten the bolt to 25 N.m (18 lb ft). Evacuate and charge the A/C system following a leak test on all fittings done with the Halogen Detector (J 39400-A).