GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Sunfire 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Flushing

Tools Required

    • J 43600 ACR 2000 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 fluids:

    • 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 orifice tube. Refer to Expansion (Orifice) Tube Replacement .
  3. Connect the A/C lines with the orifice tube removed.
  4. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  5. Install J 45268 -3 to the A/C compressor hose assembly for the Delphi compressor or install J 45268 -10 to the A/C compressor hose assembly for the Delphi CVC compressor.

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

    7. Perform the following procedure:

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

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

    Connect J 45268 -1 flush filter to the suction port of J 45268 -3 or J 45268 -10 flush adapter.

    6.2. Connect the blue hose from J 43600 to J 45268 -1 flush filter adapter.
    6.3. Connect the red hose from J 43600 to J 45268 -3 or J 45268 -10.
  7. Reverse flow refrigerant flushing is recommended for desiccant bag failure only.

    8. Perform the following procedure and replace the accumulator when the flush is complete:

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

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

    Connect J 45268 -1 flush filter to the discharge port of J 45268 -3 or J 45268 -10 flush adapter.

    7.2. Connect the blue hose from J 43600 to J 45268 -1 flush filter adapter.
    7.3. Connect the red hose from J 43600 to the suction port of J 45268 -3 or J 45268 -10.
  8. Flush the A/C system. Follow the instructions supplied with J 43600 .

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

  9. Remove J 45268 -3 or J 45268 -10 from the A/C compressor hose assembly.
    10. • Remove the A/C compressor drain plug.
    • Drain the PAG oil from the A/C compressor.
    • Rotate the compressor input shaft to assist in draining the PAG oil from the compressor.

    Notice: Refer to Fastener Notice in the Preface section.

    • Install the A/C compressor drain plug.

    Tighten
    Tighten the drain plug to 20 N·m (15 lb ft).

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

  10. Add one bottle of J 41447 directly to the A/C compressor.
  11. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  12. Inspect the orifice tube for debris.

    13. Clean or replace as needed.

  13. Install the orifice tube. Refer to Expansion (Orifice) Tube Replacement .
  14. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .

    15. Notice: Do not mix refrigerant oils. Use of incorrect refrigerant oil will cause compressor failure.

    The CVC compressor uses a low viscosity refrigerant oil, GM P/N 12378526 (Canadian P/N 88900060).

    Important: Flushing will remove all the PAG oil from the A/C system.

  15. Add the total system capacity of PAG oil to the A/C system. Refer to Refrigerant System Capacities .
  16. Leak test the fittings using J 42220 .