HVAC System - General Servicing: Removal & Installation Chevrolet Prizm I

Removal & Installation (Dakota)

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect liquid line at condenser outlet tube. Cover open refrigerant fittings to protect from moisture and dirt.
2. Using 2 wrenches, loosen tube fitting and separate front half of liquid line from rear half of liquid line. Using needle nose pliers, remove fixed orifice tube from rear half of liquid line. Note fixed orifice tube orientation for correct installation.
3. To install, reverse removal procedure. Ensure fixed orifice tube is positioned correctly. Evacuate, charge, and leak test A/C system. Ensure A/C system operates properly.

Note. On Ram Pickup, if the fixed orifice tube is faulty or plugged, the liquid line and orifice tube must be replaced as an assembly.

Removal & Installation (Ram Pickup)

Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect liquid line from evaporator inlet and condenser outlet tubes. Cover open refrigerant fittings to protect from moisture and dirt. Disconnect liquid line retaining clips. Remove liquid line and orifice tube. To install, reverse removal procedure. Evacuate, charge, and leak test A/C system. Ensure A/C system operates properly.

Fixed Orifice Tube Replacement (Except Continental, Mustang & Villager)

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. On Contour and Mystique, move power steering fluid reservoir to one side without disconnecting hoses.
2. On all models, disconnect condenser-to-evaporator discharge (liquid) line. Remove and discard "O" rings from line. Pour a small amount of refrigerant oil into inlet to lubricate orifice "O" rings.
3. Insert orifice tube remover/installer into tube and turn tool to right to engage tangs on orifice tube. (Scheme 3) Hold "T" handle of tool and slowly tighten nut down onto discharge line to slowly pull orifice tube out. If orifice tube breaks off when removal is attempted, use orifice tube extractor to pull the broken section out. (Scheme 4)
4. Ensure replacement orifice tube is fitted with "O" ring(s) lubricated with clean refrigerant oil. Insert tube with short end toward evaporator, until seated. Reconnect high pressure line. On Contour and Mystique, tighten connection to 18 ft. lbs. (24 N.m).

Scheme 3

Scheme 4

Orifice Tube Replacement Kit (Continental & Mustang)

Note. On Continental, Mustang and Villager, if orifice tube is faulty or plugged, liquid line and orifice tube must be replaced as an assembly or an orifice tube replacement kit must be installed.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove condenser-to-evaporator liquid line from vehicle. Locate orifice tube in metal portion of liquid line, near bend (indented notches or circular depression). (Scheme 5)
2. Cut a 2.5" (63.5 mm) section from liquid line, at least 1" (25.4 mm) from start of bend in line and discard. Clean out liquid line to remove contaminants.
3. Lubricate orifice tube replacement kit compression nuts and rings with refrigerant oil and install on liquid line. (Scheme 6) Ensure flow direction arrow points toward evaporator. Ensure liquid line is properly aligned for installation. Tighten compression nuts to 65-69 ft. lbs. (88-94 N.m).
4. To complete installation, reverse removal procedure. Lubricate "O" rings with refrigerant oil. Evacuate, charge and leak test system. Ensure A/C system is operating properly.

Orifice Tube Replacement Kit (Villager)

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain engine coolant to a level below thermostat. Remove upper radiator hose and bracket to gain access to condenser end of liquid line. Remove condenser-to-evaporator liquid line from vehicle.
2. Locate orifice tube in metal portion of liquid line, at indentation. (Scheme 5) Make a 4" (102 mm) index line on liquid line with indentation at the midpoint. Cut a 2.5" (63.5 mm) section from liquid line with indentation in the middle, at least 1" (25.4 mm) from start of closest bend. Clean out liquid line to remove contaminants.
3. Lubricate orifice tube replacement kit compression nuts and rings with refrigerant oil and install on liquid line. (Scheme 6) Ensure flow direction arrow points toward evaporator. Ensure index line on liquid line is properly aligned for installation. Tighten compression nuts to 65-70 ft. lbs. (88-95 N.m).
4. To complete installation, reverse removal procedure. Lubricate "O" rings with refrigerant oil. Evacuate, charge and leak test system. Ensure A/C system is operating properly.

Scheme 5

Scheme 6

Removal ("C", "E", "K" & "H" Body)

1. Locate orifice tube. See «ORIFICE TUBE LOCATION & REMOVER/INSTALLER APPLICATION»(ref-118-S16427706772000030700000) table. Discharge A/C system, using approved recovery/recycling equipment. Disconnect liquid line retaining clips.
2. Disconnect liquid line, at orifice tube location, between evaporator and condenser. Use Dual "O" Ring Joint Separator (J-38042) to hold pressure against liquid line female nut while loosening nut, if necessary. Remove and discard liquid line "O" rings using a nonmetallic tool so seal surface is not damaged.
3. Remove orifice tube using specified orifice tube remover. See «ORIFICE TUBE LOCATION & REMOVER/INSTALLER APPLICATION»(ref-118-S16427706772000030700000) table.

Installation

1. Install liquid line "O" rings. Lubricate inside of evaporator inlet line and "O" rings with refrigerant oil. Lubricate orifice tube and "O" ring with refrigerant oil. Insert orifice tube into evaporator inlet line with short screen toward condenser.
2. Tighten liquid line nut to 18 ft. lbs. (24 N.m). To complete installation, reverse removal procedure. Evacuate, charge, and test system for proper operation.

Removal ("F" Body)

Discharge A/C system, using approved recovery/recycling equipment. Disconnect negative battery cable. Disconnect A/C pressure switch connector. Use a backup wrench to hold evaporator fitting, and loosen evaporator liquid line fitting. Remove bolt. Disconnect evaporator liquid line. Remove and discard "O" rings. Using needle-nose pliers, remove orifice tube from evaporator inlet line.

1. Clean evaporator line fitting with refrigerant oil. Coat inside of inlet line and evaporator line "O" rings with refrigerant oil. Lubricate orifice tube and "O" ring with refrigerant oil and insert them into inlet line. Insert orifice tube into evaporator inlet line with long screen inlet end toward condenser.
2. Tighten bolt to 12 ft. lbs. (16 N.m). Tighten evaporator line fitting to 28 ft. lbs. (38 N.m). To complete installation, reverse removal procedure. Evacuate, charge, and test system for proper operation.

Removal ("J" & "N" Body)

1. Locate orifice tube. See «ORIFICE TUBE LOCATION & REMOVER/INSTALLER APPLICATION»(ref-118-S16427706772000030700000) table. Discharge A/C system, using approved recovery/recycling equipment. On "J" body, remove upper closeout panel. On "N" body, raise and support vehicle. On all models, disconnect condenser-to-evaporator line at condenser outlet and discard "O" rings.
2. Disconnect condenser-to-evaporator line clip on right side body rail, behind engine mount. Remove orifice tube using Orifice Tube Remover/Installer (J-26549-E) or needle-nose pliers.
3. If difficulty is encountered during removal of a plugged or restricted orifice tube, remove as much residue as possible. Using a heat gun, carefully apply heat 1/4" from dimples on condenser inlet line. Be careful not to overheat line.
4. If A/C pressure switch is located near orifice tube, remove switch to protect it from heat. While heat is being applied, grip orifice tube using orifice tube remover/installer or needle-nose pliers. Use a turning motion along with a push-pull motion to loosen and remove orifice tube.

1. Coat inside of condenser inlet line and "O" rings with refrigerant oil. Lubricate orifice tube "O" ring with refrigerant oil and insert into condenser inlet line. Insert orifice tube into condenser inlet line with shorter screen toward evaporator.
2. Connect condenser-to-evaporator line clip on right side body rail. Lubricate "O" rings and connect condenser inlet line. Tighten condenser inlet line nut to 12 ft. lbs. (16 N.m). Install closeout panel. Evacuate, charge, and test system for proper operation.

Removal ("W" Body)

1. Locate orifice tube. See «ORIFICE TUBE LOCATION & REMOVER/INSTALLER APPLICATION»(ref-118-S16427706772000030700000) table. Remove air cleaner and duct assembly. Discharge A/C system, using approved recovery/recycling equipment. Disconnect negative battery cable. Disconnect ABS modulator and A/C pressure sensor/fan switch electrical connectors.
2. Disconnect liquid line/suction line bracket. Disconnect liquid line at orifice tube. Remove orifice tube using specified orifice tube remover/installer. See «ORIFICE TUBE LOCATION & REMOVER/INSTALLER APPLICATION»(ref-118-S16427706772000030700000) table.
3. If difficulty is encountered during removal of a plugged or restricted orifice tube, remove as much residue as possible. Using a heat gun, carefully heat inlet line. If inlet line has small dimples, apply heat 1/4" from dimples. Be careful not to overheat line.
4. If A/C pressure switch is located near orifice tube, remove switch to protect it from heat. While heat is being applied, grip orifice tube using needle-nose pliers. Use a turning motion along with a push-pull motion to loosen and remove orifice tube.

1. Coat inside of inlet line and "O" ring with refrigerant oil. Lubricate orifice tube and "O" ring with refrigerant oil and insert them into inlet line. Insert orifice tube into evaporator inlet line with short screen toward condenser.
2. Tighten liquid line fitting at orifice tube to 20 ft. lbs. (27 N.m). To complete installation, reverse removal procedure. Evacuate, charge, and test system for proper operation.

Removal ("C" & "K" Series)

1. Discharge A/C system, using approved recovery/recycling equipment. On models equipped with front A/C system only, remove front grille. Using a backup wrench, loosen condenser-to-evaporator (liquid) line fitting at condenser and disconnect line.
2. On models equipped with rear A/C system, loosen condenser-to-evaporator (liquid) line fitting between junction block and evaporator. If necessary, remove air cleaner assembly.
3. On all models, remove and discard fitting "O" ring. Using Orifice Tube Remover/Installer (J-26549-E), remove orifice tube from liquid line. If difficulty is encountered during removal of a plugged or restricted orifice tube, remove as much residue as possible.
4. Using a heat gun, carefully apply heat 1/4" from dimples on liquid line. Be careful not to overheat line. If A/C pressure switch is located near orifice tube, remove switch to protect it from heat.
5. While heat is being applied, grip orifice tube using orifice tube remover/installer. Use a turning motion along with a push-pull motion to loosen and remove orifice tube.

1. Clean liquid line fitting with refrigerant oil. Coat inside of liquid line and "O" ring with refrigerant oil. Lubricate orifice tube and "O" ring with refrigerant oil and insert them into liquid line. Insert longer orifice tube screen (inlet end) into condenser outlet line first, toward condenser.
2. Tighten liquid line fitting to 18 ft. lbs. (24 N.m). To complete installation, reverse removal procedure. Evacuate, charge, and test system for proper operation.

Removal ("G", "L" & "M" Series)

1. Discharge A/C system, using approved recovery/recycling equipment. Using a backup wrench, loosen evaporator inlet (liquid) line fitting at evaporator. Disconnect inlet line. Remove and discard "O" ring(s). Using Orifice Tube Remover/Installer (J-26549-E), remove orifice tube from liquid line.
2. If difficulty is encountered during removal of a plugged or restricted orifice tube, remove as much residue as possible. Using a heat gun, carefully apply heat 1/4" from dimples on liquid line. Be careful not to overheat line.
3. If A/C pressure switch is located near orifice tube, remove switch to protect it from heat. While heat is being applied, grip orifice tube using orifice tube remover/installer. Use a turning motion along with a push-pull motion to loosen and remove orifice tube.

1. Clean liquid line fitting with refrigerant oil. Add one ounce of refrigerant oil to system. Coat inside of liquid line and "O" rings with refrigerant oil. Lubricate orifice tube and "O" ring with refrigerant oil and insert them into liquid line. Insert shorter orifice tube screen into liquid line first with long screen (inlet end) toward condenser.
2. Tighten liquid line fitting to 20 ft. lbs. (27 N.m). To complete installation, reverse removal procedure. Evacuate, charge, and test system for proper operation.

Removal ("U" Series)

1. Remove air cleaner and duct assembly. Discharge A/C system, using approved recovery/recycling equipment. Using a backup wrench, loosen condenser outlet (liquid) line fitting at orifice tube. Disconnect liquid line. Remove and discard "O" rings. Using needle-nose pliers, remove orifice tube from liquid line.
2. If difficulty is encountered during removal of a plugged or restricted orifice tube, remove as much residue as possible. Using a heat gun, carefully apply heat 1/4" from dimples on liquid line. Be careful not to overheat line.
3. If A/C pressure switch is located near orifice tube, remove switch to protect it from heat. While heat is being applied, grip orifice tube using needle-nose pliers. Use a turning motion along with a push-pull motion to loosen and remove orifice tube.

1. Clean liquid line fitting with refrigerant oil. Add one ounce of refrigerant oil to system. Coat inside of liquid line and "O" rings with refrigerant oil. Lubricate orifice tube and "O" ring with refrigerant oil and insert them into liquid line. Insert orifice tube into liquid line with long screen (inlet end) toward condenser.
2. Tighten liquid line fitting to 20 ft. lbs. (27 N.m). To complete installation, reverse removal procedure. Evacuate, charge, and test system for proper operation.

ORIFICE TUBE LOCATION & REMOVER/INSTALLER APPLICATION

JEEP

Note. On Cherokee and Grand Cherokee, fixed orifice tube is located in the liquid line. If the fixed orifice tube is faulty or plugged, the liquid line and orifice tube must be replaced as an assembly.

Removal & Installation (Cherokee & Grand Cherokee)

Disconnect battery negative cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect liquid line retaining clips. Disconnect liquid line from evaporator inlet and condenser outlet tubes. Cover open refrigerant fittings to protect from moisture and dirt. Remove liquid line and orifice tube. To install, reverse removal procedure. Evacuate, charge, and leak test A/C system. Ensure A/C system operates properly.

Removal & Installation (Wrangler)

1. Disconnect battery negative cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect liquid line at condenser outlet tube. Cover open refrigerant fittings to protect from moisture and dirt.
2. Using needle nose pliers, remove fixed orifice tube from condenser outlet tube. Note fixed orifice tube orientation for correct installation. To install, reverse removal procedure. Ensure fixed orifice tube is positioned correctly. Evacuate, charge, and leak test A/C system. Ensure A/C system operates properly.