GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Malibu 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Flushing

Special Tools

    • 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
    • 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.


    Object Number: 1162447 Size: SH

    Note: Inspect and lubricate J 45268 fitting O-rings. Refer to O-Ring Replacement.

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

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:

    Note: Inspect and lubricate J 45268 fitting O-rings. Refer to O-Ring Replacement.

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

Flush Procedure

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

  1. Recover refrigerant. Refer to Refrigerant Recovery and Recharging.
  2. Remove thermal expansion valve (TXV). Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement.
  3. Install TXV stud onto J 45268-115.
  4. Install new sealing washers onto evaporator core. Refer to Sealing Washer Replacement.
  5. Install J 45268-115 in place of TXV.

    6. Caution: Refer to Fastener Caution in the Preface section.

  6. Install TXV mounting bolts and tighten to 7 N·m (62 lb in).
  7. Install new washers onto liquid line and suction hose. Refer to Sealing Washer Replacement.
  8. Connect liquid line and suction hose to J 45268-115.
  9. Install TXV block fitting nut and tighten to 27 N·m (20 lb ft).
  10. Remove A/C compressor. Refer to Air Conditioning Compressor Replacement.
  11. Remove A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement.

    12. Object Number: 787687 Size: SH

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

  12. Service filter with ACDelco P/N GF 470, before each flush.

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

  13. Install J 45268-10 to compressor hose assembly.
  14. Connect J 45268-1 flush filter to J 45268-7 flush adapter.
  15. Connect blue hose from J 43600 to J 45268-1 flush filter adapter.
  16. Connect red hose from J 43600 to J 45268-8 flush adapter.

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

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

    22. 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.

  22. If you will reinstall the removed A/C compressor, perform the following procedure:
    23. 22.1. Remove A/C compressor drain plug.
    22.2. Drain PAG oil from A/C compressor. Rotate compressor input shaft to assist in draining the PAG oil from compressor.
    22.3. Add the total system capacity of PAG oil to A/C compressor. Refer to Refrigerant System Capacities.

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

    22.4. Add one bottle of J 41447 .
    22.5. Install A/C compressor drain plug and tighten to 15 N·m (11 lb ft).

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

  23. Install A/C compressor. Refer to Air Conditioning Compressor Replacement.
  24. Install new A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement.
  25. Remove TXV block fitting nut.
  26. Disconnect liquid line and suction line from J 45268-115.
  27. Remove TXV bolts retaining J 45268-115.
  28. Remove J 45268-115.
  29. Inspect TXV for debris. Clean or replace as needed.
  30. Install TXV. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement.
  31. Evacuate and recharge A/C system. Refer to Refrigerant Recovery and Recharging.
  32. Leak test fittings using J 42220 .