Flushing w/o Auxiliary A/C
Tools Required
• | J 41447 R-134A
- A/C Tracer Dye - Box of 24 |
• | J 42220 Universal
12V Leak Detection Lamp |
• | J 43600 ACR 2000 Air
Conditioning Service Center |
Important: Flushing 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 |
• | Refrigerant contamination |
Forward Flushing Setup
Important: Forward flow refrigerant flushing is recommended for contaminated refrigerant
or PAG oil.
Important: Inspect and lubricate the J 45268
fitting O-rings. Refer to
O-Ring Replacement
.
- Install the J 45268-7 (2) onto the suction line adapter block J 45268-13
(1).
- Install the J 45268-8 (3) onto the discharge line adapter block
J 45268-12 (4).
Reverse Flushing Setup
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:
Important: Inspect and lubricate the J 45268
fitting O-rings. Refer to
O-Ring Replacement
.
- Install the J 45268-8 (2) onto the suction line adapter block J 45268-13
(1).
- Install the J 45268-7 (3) onto the discharge line adapter block
J 45268-12 (4).
Flush Procedure
Important: Warmer engine or ambient temperatures decreases the refrigerant recovery time
during the A/C flush procedure.
- Recover the refrigerant. Refer to
Refrigerant Recovery and Recharging
.
- Remove the thermal expansion valve (TXV).
Refer to
Thermal Expansion Valve Replacement
.
- Install new O-rings onto the evaporator core and A/C lines. Refer
to
O-Ring Replacement
.
- Install the A/C lines into J 45268-110.
- Install J 45268-110 onto the evaporator core.
- Install the TXV line bracket.
- Install TXV mounting bolts.
Tighten
Tighten the bolts to 3.5 N·m (31 lb in).
- Remove the A/C compressor. Refer to
Air Conditioning Compressor Replacement
.
Important: The filter inside J 45268-1 is serviceable. Remove and discard the check
valve from the filter.
- Service the filter with ACDelco P/N GF 470, before each flush.
Important: Install new O-rings onto the A/C discharge and suction lines. Refer to
O-Ring Replacement
.
- Install the J 45268-13 to the A/C suction line.
- Install the J 45268-12 to the A/C discharge line.
- Connect
the J 45268-1 flush filter to the J 45268-7 flush fitting.
- Connect the blue hose from the J 43600
to J 45268-1 flush filter adapter.
- Connect the red hose from the J 43600
to J 45268-8 flush fitting.
Important: Close the valve on the external refrigerant tank, before starting the flush
process.
- Flush the A/C system. Follow the instructions supplied with the J 43600
.
- Disconnect the red hose from the J 43600
to J 45268-8 flush fitting.
- Disconnect the blue hose from the J 43600
to J 45268-1 flush filter adapter.
- Disconnect the J 45268-1 flush filter from the J 45268-7
flush fitting.
- Remove the J 45268-12 from the A/C discharge line.
- Remove the J 45268-13 from the A/C suction line.
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.
- If you will reinstall the removed A/C compressor, perform the following procedure:
21.1. | Drain the PAG oil from the A/C compressor. Rotate the compressor input
shaft to assist in draining the PAG oil from the compressor. |
| Important: Rotating the compressor hub assembly when adding PAG oil to the A/C compressor
suction port will draw the PAG oil into the crankcase chamber and prevent overflow
.
|
21.2. | Add the total system capacity of PAG oil into the suction port of the A/C compressor
while slowly rotating the A/C compressor hub assembly. Refer to
Refrigerant System Capacities
. |
| Important: Flushing will remove the fluorescent leak detection dye from the A/C system.
|
21.3. | Add one bottle of J 41447
directly
into the suction port of the A/C compressor while slowly rotating the A/C compressor
hub assembly. |
Important: A new service compressor is shipped with a full charge of PAG oil. Refer to
Refrigerant System Capacities
.
- Install the A/C compressor. Refer to
Air Conditioning Compressor Replacement
.
- Remove the TXV mounting bolts.
- Remove the TXV line bracket.
- Remove J 45268-110 from the evaporator core.
- Remove the A/C lines from J 45268-110.
- Inspect the TXV for debris. Clean or replace as needed.
- Replace the desiccant bag. Refer to
Air Conditioning Refrigerant Desiccant Replacement
.
- Evacuate and recharge the A/C system. Refer to
Refrigerant Recovery and Recharging
.
- Leak test the fittings using J 42220
.
Flushing w/Auxiliary A/C
Tools Required
• | J 41447
R-134A - A/C Tracer Dye - Box of 24 |
• | J 42220
Universal 12V Leak Detection Lamp |
• | J 43600
ACR 2000 Air Conditioning Service Center |
Important: Vehicles with auxiliary A/C must flush both the front and auxiliary A/C System to adequately flush the entire A/C System.
Flushing 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 |
• | Refrigerant contamination |
Forward Flushing Setup
Important: Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil.
Important: Inspect and lubricate the
J 45268
fitting O-rings. Refer to
O-Ring Replacement
.
- Install the J 45268-7 (2) onto the suction line adapter block J 45268-13 (1).
- Install the J 45268-8 (3) onto the discharge line adapter block J 45268-12 (4).
Reverse Flushing Setup
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:
Important: Inspect and lubricate the
J 45268
fitting O-rings. Refer to
O-Ring Replacement
.
- Install the J 45268-8 (2) onto the suction line adapter block J 45268-13 (1).
- Install the J 45268-7 (3) onto the discharge line adapter block J 45268-12 (4).
Flush Procedure - Front System
Important: Warmer engine or ambient temperatures decreases the refrigerant recovery time during the A/C flush procedure.
- Recover the refrigerant. Refer to
Refrigerant Recovery and Recharging
.
- Remove the front thermal expansion valve (TXV). Refer to
Thermal Expansion Valve Replacement
.
- Inspect the O-rings on the evaporator core and A/C lines and replace as necessary . Refer to
O-Ring Replacement
.
- Install the A/C lines into J 45268-110.
- Install J 45268-110 onto the evaporator core.
- Install the TXV line bracket.
- Install TXV mounting bolts.
Tighten
Tighten the bolts to 3.5 N·m (31 lb in).
- Remove the A/C compressor. Refer to
Air Conditioning Compressor Replacement
.
Important: The filter inside J 45268-1 is serviceable. Remove and discard the check valve from the filter.
- Service the filter with ACDelco P/N GF 470, before each flush.
Important: Arrange the J 45268-7 flush fitting and J 45268-8 flush fitting in the forward flushing setup.
- Inspect the O-rings on the A/C discharge and suction lines and replace as necessary. Refer to
O-Ring Replacement
- Install the J 45268-13 to the A/C suction line.
- Install the J 45268-12 to the A/C discharge line.
- Connect the J 45268-1 flush filter to the J 45268-7 flush fitting.
- Connect the blue hose from the
J 43600
to J 45268-1 flush filter adapter.
- Connect the red hose from the
J 43600
to J 45268-8 flush fitting.
Important: Close the valve on the external refrigerant tank, before starting the flush process.
- Flush the A/C system. Follow the instructions supplied with the
J 43600
.
- Remove the front TXV mounting bolts.
- Remove the front TXV line bracket.
- Remove J 45268-110 from the evaporator core.
- Remove the A/C lines from J 45268-110.
- Inspect the TXV for debris. Clean or replace as needed.
Important: Do not install the instrument panel (I/P) until after the forward flushing of the auxiliary system procedure is completed.
- Install the TXV. Refer to
Thermal Expansion Valve Replacement
.
Flush Procedure - Auxiliary A/C System
- Remove the auxiliary TXV. Refer to
Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement
.
- Install the J 45268-111 in place of the auxiliary TXV.
- Install auxiliary TXV assembly onto the evaporator core.
- Install auxiliary TXV mounting bolts.
Tighten
Tighten the bolts to 3.5 N·m (31 lb in).
Important: It is not necessary to reinstall the auxiliary evaporator core into the auxiliary HVAC module prior to flushing.
- Connect the auxiliary evaporator core inlet line to the auxiliary evaporator core.
Tighten
Tighten the nut to 9 N·m (80 lb in).
- Connect the auxiliary evaporator core outlet line to the auxiliary evaporator core.
Tighten
Tighten the nut to 9 N·m (80 lb in).
Important: The filter inside J 45268-1 is serviceable. Remove and discard the check valve from the filter.
- Service the filter with ACDelco P/N GF 470, before each flush.
Important: Close the valve on the external refrigerant tank, before starting the flush process.
- Flush the auxiliary A/C System. Follow the instructions supplied with the
J 43600
.
- Disconnect the red hose from the
J 43600
to J 45268-8 flush fitting.
- Disconnect the blue hose from the
J 43600
to J 45268-1 flush filter adapter.
- Disconnect the J 45268-1 flush filter from the J 45268-7 flush fitting.
- Remove the J 45268-12 from the A/C discharge line.
- Remove the J 45268-13 from the A/C suction line.
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.
- If you will reinstall the removed A/C compressor, perform the following procedure:
14.1. | Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor. |
| Important: Rotating the compressor hub assembly when adding PAG oil to the A/C compressor suction port will draw the PAG oil into the crankcase chamber and prevent overflow .
|
14.2. | Add the total system capacity of PAG oil into the suction port of the A/C compressor while slowly rotating the A/C compressor hub assembly. Refer to
Refrigerant System Capacities
. |
| Important: Flushing will remove the fluorescent leak detection dye from the A/C system.
|
14.3. | Add one bottle of J 41447 fluorescent dye directly into the A/C compressor suction port while slowly rotating the A/C compressor hub assembly. |
Important: A new service compressor is shipped with a full charge of PAG oil. Refer to
Refrigerant System Capacities
.
- Install the A/C compressor. Refer to
Air Conditioning Compressor Replacement
.
- Remove the auxiliary evaporator core outlet line to auxiliary evaporator core nut.
- Disconnect the auxiliary evaporator core outlet line from the auxiliary evaporator core.
- Remove the auxiliary evaporator core inlet line to auxiliary evaporator core nut.
- Disconnect the auxiliary evaporator core inlet line to the auxiliary evaporator core.
Tighten
Tighten the nut to 9 N·m (80 lb in).
- Remove the auxiliary TXV assembly mounting bolts.
- Remove the auxiliary TXV assembly.
- Remove J 45268-111 from the auxiliary TXV assembly.
- Inspect the auxiliary TXV for debris. Clean or replace as necessary.
- Install the auxiliary TXV and auxiliary HVAC module back into the vehicle. Refer to
Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement
.
Important: Debris may form at the front TXV when flushing the auxiliary A/C System. It is necessary to remove and inspect the TXV to maintain optimal A/C System performance.
- Remove and inspect the front TXV assembly for debris. Refer to
Thermal Expansion Valve Replacement
.
Clean or replace as necessary.
- Install the front TXV. Refer to
Thermal Expansion Valve Replacement
.
- Replace the desiccant bag. Refer to
Air Conditioning Refrigerant Desiccant Replacement
.
- Evacuate and recharge the A/C System. Refer to
Refrigerant Recovery and Recharging
.
- Leak test the fittings using
J 42220
.