GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Montana - 4WD 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Flushing

Tools Required

    • J 43600 Air Conditioning Service Center
    • J 45268 Flush Adapter Kit
    • J 41447 Leak Detection Dye
    • J 42220 Universal 12V Leak Detection Lamp

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

Flushing is intended to remove the following contaminants:

    • Contaminated PAG oil
    • Desiccant, following a desiccant bag failure
    • Overcharge of PAG oil
    • Refrigerant contamination

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

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the TXV. Refer to Thermal Expansion Valve Replacement .
  3. Install J 45268-103 in place of the TXV.
  4. Remove the auxiliary TXV. Refer to Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement .
  5. Install J 45268-107 in place of the auxiliary TXV.
  6. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  7. Install J 45268-5 to the discharge hose.
  8. Install J 45268-4 to the suction hose.

    9. Object Number: 787687 Size: SH
  9. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil.

    10. Perform the following procedure:

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

    9.1. Service the filter with ACDelco P/N GF 470, before each flush.
    9.2. Connect J 45268-1 to the suction port of J 45268-4.
    9.3. Connect the blue hose from J 43600 to J 45268-1 flush filter adapter.
    9.4. Connect the red hose from J 43600 to J 45268-5 flush adapter.
  10. Reverse flow refrigerant flushing is recommended for desiccant bag failure. Replace the receiver dehydrator when the A/C flush is complete and perform the following procedure:

    11.         Important: The filter inside J 45268-1 is serviceable.

    10.1. Service the filter with ACDelco P/N GF 470, before each flush.
    10.2. Connect J 45268-1 to the discharge port of J 45268-5.
    10.3. Connect the blue hose from J 43600 to J 45268-1 flush filter adapter.
    10.4. Connect the red hose from J 43600 to the suction port of J 45268-4 flush adapter.

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

  11. Flush the front A/C system. Follow the instructions supplied with the J 43600 .

    12. Important: Flush the front A/C system before flushing the auxiliary A/C system.

  12. If the vehicle is equipped with rear A/C, flush the auxiliary A/C system separately.
    13. 12.1. Remove J 45268-107 from the auxiliary evaporator core.
    12.2. Remove J 45268-103.
    12.3. Install J 45268-103 to the auxiliary evaporator core.
    12.4. Install J 45268-107.
  13. Flush the auxiliary A/C system. Follow the instructions supplied withJ 43600 .
  14. Remove J 45268-5 from the discharge hose.
  15. Remove J 45268-4 from the suction hose.

    16. 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.

  16. If the removed A/C compressor is being reinstalled, perform the following procedure:
    17. 16.1. Drain the PAG oil from the A/C compressor.

    Rotate the compressor input shaft to assist in draining the PAG oil from the compressor.

    16.2. Add the total system capacity of PAG oil to the A/C compressor. Refer to Refrigerant System Capacities .
  17. If you will replace the A/C compressor after flushing the system, perform the following procedure:
    18. 17.1. A new service compressor is shipped with PAG oil. Refer to the Refrigerant System Capacities .
    17.2. If the service compressor is shipped with PAG oil, DO NOT drain the new PAG oil from the compressor.
    17.3. Deduct the amount of PAG oil shipped with the service compressor from the amount of PAG oil listed in the capacities table. Refer to Refrigerant System Capacities .

    Add the calculated amount to the compressor, as needed.

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

  18. Add one bottle of J 41447 directly to the A/C compressor.
  19. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  20. Remove J 45268-103.
  21. Inspect the TXV for debris. Clean or replace as needed.
  22. Install the auxiliary TXV. Refer to Auxiliary Air Conditioning Evaporator Thermal Expansion Valve Replacement .
  23. Remove J 45268-107.
  24. Inspect the TXV for debris. Clean or replace as needed.
  25. Install the TXV. Refer to Thermal Expansion Valve Replacement .
  26. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  27. Leak test the fittings using J 42220 .