Flushing

FLUSHING

TOOLS REQUIRED
- 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

IMPORTANT: Flushing with the J 43600 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




1. Install both J 45268-9 (2) onto the J 45268-10 (3).

IMPORTANT:
- Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil.
- Inspect and lubricate the sealing washers J 45268.

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




1. Install both J 45268-9 (2) onto the J 45268-10 (3).

IMPORTANT:
- 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:
- Inspect and lubricate the J 45268 sealing washers.

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

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

2. Remove the thermal expansion valve (TXV).




3. Install the stud onto the J 45268-115.
4. Install new sealing washers onto the evaporator core.
5. Install J 45268-115 in place of the TXV.

NOTE: Refer to Fastener Notice.

6. Install TXV mounting bolts.

Tighten the bolts to 7 N.m (62 lb in).

7. Install new washers onto the condenser tube and evaporator hose.
8. Connect the condenser tube and evaporator hose to the J 45268-115.
9. Install the TXV block fitting nut.

Tighten the nut to 20 N.m (15 lb ft).

10. Remove the A/C compressor.
11. Remove the A/C refrigerant filter.




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

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

13. Install the J 45268-10 to the compressor hose assembly.

IMPORTANT: Install new sealing washers onto the compressor hose assembly.
Assure that the suction and discharge ports on the J 45268-10 correspond to the suction and discharge ports on 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.
17. Flush the A/C system. Follow the instructions supplied with the J 43600.

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

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

IMPORTANT: 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.




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. Refer to Refrigerant System Capacities.
4. Add one bottle of J 41447 directly into the A/C compressor.

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

5. Install the A/C compressor drain plug.

Tighten the drain plug to 15 N.m (11 lb ft).

23. Install the A/C compressor.

IMPORTANT: A new service compressor is shipped with a partial charge of PAG oil. Refer to Refrigerant System Capacities.

24. Install the A/C refrigerant filter.
25. Remove the TXV block fitting nut.
26. Disconnect the condenser tube and evaporator hose 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.
31. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
32. Leak test the fittings using J 42220.