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Flushing




Flushing

Special Tools
* J 41447 - R-134a-Leak Detection Dye
* J 42220 - Universal 12V Leak Detection Lamp
* J 43600 - ACR 2000 Air Conditioning Service Center
* J 45268 - A/C Flush Adapter Kit

Note: Flushing with the ACR 2000 is not intended to remove metal from the A/C system.

Flushing is intended to remove the following:

* Contaminated polyalkylene glycol (PAG) oil
* Desiccant, following a desiccant bag failure
* Overcharge of PAG oil
* Refrigerant contamination

Forward Flushing Setup

Note: Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil.





Note: Inspect and lubricate the J 45268 fitting O-rings. Refer to Air Conditioning O-Ring Seal Replacement (Air Conditioning O-Ring Seal Replacement).

1. Install both J 45268-9 (2) onto the J 45268-10 (3).
2. Install the J 45268-7 (4) onto the suction side of the J 45268-10 (3).
3. Install the J 45268-8 (1) onto the discharge side of the J 45268-10 (3).

Reverse Flushing Setup

Note: Reverse flow refrigerant flush is recommended for desiccant bag failure. Replace the condenser/receiver dehydrator assembly when the A/C flush is complete and perform the following procedure:





Note: Inspect and lubricate the J 45268 fitting O-rings. Refer to Air Conditioning O-Ring Seal Replacement (Air Conditioning O-Ring Seal Replacement).

1. Install both J 45268-9 (2) onto the J 45268-10 (3).
2. Install the J 45268-8 (1) onto the suction side of the J 45268-10 (3).
3. Install the J 45268-7 (4) onto the discharge side of the J 45268-10 (3).

Flush Procedure

Note: Warmer engine or ambient temperatures decreases the refrigerant recovery time during the A/C flush procedure.

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Belt Driven Compressor) (Refrigerant Recovery and Recharging (Belt Driven Compressor)).
2. Remove the thermal expansion valve (TXV). Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement (Service and Repair).




3. Install the stud onto the J 45268-115.
4. Install new sealing washers onto the evaporator core. Refer to Air Conditioning System Seal Replacement (Air Conditioning System Seal Replacement).
5. Install J 45268-115 in place of the TXV.
6. Install TXV mounting bolts and tighten to 7 Nm (62 lb in).
7. Install new washers onto the rear evaporator line assembly. Refer to Air Conditioning System Seal Replacement (Air Conditioning System Seal Replacement).
8. Connect the rear evaporator line assembly to the J 45268-115.
9. Install the TXV block fitting nut and tighten to 20 Nm (15 lb ft).
10. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (Removal and Replacement).
11. Remove the A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement (Service and Repair).





Note: The filter inside J 45268-1 is serviceable. Remove and discard the check valve from the filter.

12. Service the filter with AC Delco P/N GF 470, before each flush.

Note: Install new sealing washers onto the compressor hose assembly. Refer to Air Conditioning System Seal Replacement (Air Conditioning System Seal Replacement).

Assure that the suction and discharge ports on the J 45268-10 correspond to the suction and discharge ports on the compressor hose assembly.

13. Install the J 45268-10 to the compressor hose assembly.
14. Connect the J 45268-1 flush filter to the J 45268-7 flush adapter.




15. Connect the blue hose from the J 43600 to J 45268-1 flush filter adapter.
16. Connect the red hose from the J 43600 to J 45268-8 flush adapter.

Note: Close the valve on the external refrigerant tank, before starting the flush process.

17. Flush the A/C system. Follow the instructions supplied with the J 43600 .
18. Disconnect the red hose from the J 43600 to J 45268-8 flush adapter.
19. Disconnect the blue hose from the J 43600 to J 45268-1 flush filter adapter.
20. Disconnect the J 45268-1 flush filter from the J 45268-10 flush adapter.
21. Remove the J 45268-10 from the compressor hose assembly.

Note: Flushing will remove all the PAG oil from the A/C system.

The A/C system must be replenished with the correct amount of PAG oil.

22. If you will reinstall the removed A/C compressor, perform the following procedure:




1. Remove the A/C compressor drain plug.
2. Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor.
3. Add the total system capacity of PAG oil to the crankcase of the A/C compressor.

Note: Flushing will remove the fluorescent leak detection dye from the A/C system.

4. Add one bottle of J 41447 directly into the A/C compressor.
5. Install the A/C compressor drain plug and tighten to 15 Nm (11 lb ft).

Note: A new service compressor is shipped with a full charge of PAG oil.

23. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (Removal and Replacement).
24. Install the A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement (Service and Repair).
25. Remove the TXV block fitting nut.
26. Disconnect the rear evaporator line assembly from the J45268-115.




27. Remove the TXV bolts retaining the J 45268-115.
28. Remove the J 45268-115.
29. Inspect the TXV for debris. Clean or replace as needed.
30. Install the TXV. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement (Service and Repair).
31. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Belt Driven Compressor) (Refrigerant Recovery and Recharging (Belt Driven Compressor)).
32. Leak test the fittings using J 42220 .

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