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Flushing




Flushing

Special Tools

* BO-42220 - Universal 12V Leak Detection Lamp

* GE-41447 - R-134A A/C Tracer Dye Box of 24

* GE-45268 - A/C Flush Adapter Kit

For equivalent regional tools, refer to Special Tools Tools and Equipment.

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 GE-45268 - adapter kit fitting O-rings. Refer to Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement.

1. Install both GE 45268-9 - fitting O-ring onto GE 45268-10 - adapter.

2. Install GE 45268-8 - fitting O-ring onto suction side of GE 45268-10 - adapter.

3. Install GE 45268-7 - fitting O-ring onto discharge side of GE 45268-10 - adapter.

Reverse Flushing Setup

Note:

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

* Inspect and lubricate GE-45268 - adapter kit fitting O-rings. Refer to Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement.

1. Install both GE-45268-9 - fitting O-ring onto GE-45268-10 - adapter.

2. Install GE-45268-8 - fitting O-ring onto suction side of GE-45268-10 - adapter.

3. Install GE-45268-7 - fitting O-ring onto discharge side of GE-45268-10 - adapter.

Flush Procedure

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

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

2. Remove the thermal expansion valve (TXV). Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement Service and Repair.

3. Install the TXV stud onto GE 45268-115 - adapter.

4. Install new sealing washers onto evaporator core. Refer to Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement.

5. Install GE-45268-115 - adapter in place of the TXV, using an oversized seal washer.

Caution:
Refer to Fastener Caution Fastener Caution.

6. Install the TXV mounting bolts and tighten to 15 Nm (11 lb in).

7. Install new washers onto liquid line and suction hose. Refer to Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement.

8. Connect liquid line and suction hose to GE-45268-115 - adapter using an oversized seal washer.

9. Install the TXV block fitting nut and tighten to 19 Nm (14 lb in).

10. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (1.8L LUW and LWE) Air Conditioning Compressor ReplacementAir Conditioning Compressor Replacement (1.4L LUV) Air Conditioning Compressor Replacement.





11. Remove the A/C refrigerant filter (1). Refer to Air Conditioning Refrigerant Desiccant Replacement Service and Repair.

Note:
The filter inside GE-45628-1 - adapter is serviceable. Remove and discard check valve from the filter.

12. Service the filter before each flush.

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

13. Install new sealing washers onto A/C compressor and condenser hose. Refer to Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement. Assure that suction and discharge ports on GE 45268-10 - adapter correspond to suction and discharge ports on A/C compressor to condenser hose.

14. Install GE-45268-10 - filter adapter to the A/C compressor to condenser hose.

15. Connect GE-45268-1 - filter to J-45268-7 - adapter.

16. Connect blue hose from A/C filling device to GE-45268 - adapter.

17. Connect red hose from A/C filling device to GE-45268 - adapter.

18. Disconnect blue hose from A/C filling device to GE-45268-1 - adapter.

19. Disconnect GE-45268-1 - adapter from GE-45268-10 - adapter.

20. Remove GE-45268-10 - adapter from the A/C compressor to condenser hose.

Note:
Flushing will remove all PAG oil from the A/C system. The A/C system must be replenished with the correct amount of PAG oil.

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

* Remove the A/C compressor drain plug. Refer to Air Conditioning Compressor Oil Drain Plug Replacement (1.8L LUW and LWE) Air Conditioning Compressor Oil Drain Plug ReplacementAir Conditioning Compressor Oil Drain Plug Replacement (1.4L LUV) Air Conditioning Compressor Oil Drain Plug Replacement.

* Drain PAG oil from the A/C compressor. Rotate compressor input shaft to assist in draining the PAG oil from compressor.

* Add the total system capacity of PAG oil to A/C compressor. Refer to Refrigerant System Specifications Specifications.

* Add one bottle of GE-41447 - tracer dye.

* Install the A/C compressor drain plug. Refer to Air Conditioning Compressor Oil Drain Plug Replacement (1.8L LUW and LWE) Air Conditioning Compressor Oil Drain Plug ReplacementAir Conditioning Compressor Oil Drain Plug Replacement (1.4L LUV) Air Conditioning Compressor Oil Drain Plug Replacement.

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

22. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (1.8L LUW and LWE) Air Conditioning Compressor ReplacementAir Conditioning Compressor Replacement (1.4L LUV) Air Conditioning Compressor Replacement.

23. Install new A/C refrigerant filter. Refer to Air Conditioning Refrigerant Desiccant Replacement Service and Repair.

24. Remove the TXV block fitting nut.

25. Disconnect liquid line and suction line from GE-45268-115 - adapter.

26. Remove the TXV bolts retaining GE-45268-115 - adapter.

27. Remove GE-45268-115 - adapter.

28. Inspect the TXV for debris. Clean or replace as needed.

29. Install the TXV. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement Service and Repair.

30. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

31. Leak test fittings using BO-42220 - lamp.

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