Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L or Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
3. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
4. Remove the condenser tube. Refer to Condenser Tube Replacement .
5. Remove the expansion (orifice) tube:

5.1.	Use needle-nose pliers in order to grip the orifice tube.

5.2.	Use a turning motion along with a push-pull motion in order to loosen the impacted orifice tube.

5.3.	Remove the orifice tube.





Important: DO NOT use any solvents or chemicals to clean the expansion (orifice) tube porous plastic inlet filter.

6. Inspect the expansion (orifice) tube for the following conditions and clean or replace with a new tube as indicated:

•	Broken plastic frame (1) ; replace tube

•	Inlet filter (3) damaged or plugged with fine gritty material; replace tube

•	Inlet filter (3) coated with metal chips, flakes, or slivers; coating may be removed with low pressure shop air ONLY and reused if cleaned satisfactorily

•	If reusing the tube, discard the O-ring seals (2)

Important: Lubricate the new O-ring seals (2) with mineral base 525 viscosity refrigerant oil.

1. Install the new O-ring seals (2), if reusing the orifice tube.
2. CAREFULLY grasp the edge of the expansion (orifice) tube (1) without touching the inlet filter (porous plastic) (3) and insert into the condenser tube until fully seated.
3. Install the condenser tube. Refer to Condenser Tube Replacement .
4. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L or Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
7. Leak test the fittings of the component using J 39400-A .