GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2008 🢒 SKY 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Flushing

Flushing Non-HP5

Tools Required

    • J 43600 ACR 2000 Air Conditioning Service Center
    • J 45268 Flush Adapter Kit
    • J 41447 R134A A/C Tracer Dye - Box of 24
    • 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:

    • Contaminated polyalkylene glycol (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 thermal expansion valve (TXV). Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement.
  3. Install the stud for the J 45268 kit onto the J 45268-115.
  4. Install the J 45268-115 in place of the TXV.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the TXV mounting bolts.

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

  6. Connect the evaporator line to the J 45268-115.
  7. Install the TXV block fitting nut.

    8. Tighten
    Tighten the bolts to 27 N·m (20 lb ft).

  8. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement.
  9. Install the appropriate compressor block adapter to the A/C compressor hose assembly:
    10. • LAT engine - J-45268-10
    • LE5 and LZ4 engines - GE-45268-127
    • LY7 engine - J-45268 and J-45268-13
  10. Install the nut and bolt from the J 45268 kit to the and compressor block adapter.

    11. Tighten
    Tighten the bolts to 27 N·m (20 lb ft).

  11. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil.

    12. Perform the following procedure:


    Object Number: 787687 Size: SH

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

    11.1. Service the filter with ACDelco P/N GF 470, before each flush.
    11.2. Install the port plugs J 45268-9 onto the compressor block adapter.
    11.3. Install the fitting J 45268-7 onto the compressor block adapter.
    11.4. Install the fitting J 45268-8 onto the compressor block adapter.
    11.5. Connect J 45268-1 flush filter to the suction port of J 45268-7 flush adapter.
    11.6. Connect the blue hose from the J 43600 to the J 45268-1 flush filter adapter.
    11.7. Connect the red hose from the J 43600 to the J 45268-8 flush adapter.
  12. Reverse flow refrigerant flush is recommended for desiccant bag failure. Replace the receiver dehydrator when the A/C flush is complete and perform the following procedure:

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

    12.1. Service the filter with ACDelco P/N GF 470, before each flush.
    12.2. Install the port plugs J 45268-9 onto the compressor block adapter.
    12.3. Install the fitting J 45268-7 onto the compressor block adapter.
    12.4. Install the fitting J 45268-8 onto the compressor block adapter.
    12.5. Connect J 45268-1 flush filter to the discharge port of J 45268-7 flush adapter.
    12.6. Connect the blue hose from J 43600 to the J 45268-1 flush filter adapter.
    12.7. Connect the red hose from J 43600 to the J 45268-8 flush adapter.

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

  13. Flush the A/C system. Follow the instructions supplied with the J 43600 .
  14. Disconnect the red hose on the J 43600 from the compressor block adapter.
  15. Disconnect the blue hose on the J 43600 from the J 45268-1.
  16. Remove J 45268-1 from the compressor block adapter.
  17. Remove the compressor block adapter from the A/C compressor hose assembly.

    18. 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.

  18. If you will reinstall the removed A/C compressor, perform the following procedure:
    19. 18.1. 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: Flushing will remove the fluorescent leak detection dye from the A/C system.

    18.2. Add one bottle of J 41447 .
    18.3. Add the total system capacity of PAG oil to the A/C compressor. Refer to Refrigerant System Capacities.
  19. If you will replace the A/C compressor after flushing the system, perform the following procedure:
    20. 19.1. The service compressor is shipped with PAG oil, DO NOT drain the new PAG oil from the compressor.
    19.2. 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.
    19.3.  Add the calculated amount to the compressor, as needed.

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

    19.4. Add one bottle of J 41447 .
  20. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement.
  21. Remove J 45268-115.
  22. Inspect the TXV for debris. Clean or replace as needed.
  23. Install the TXV. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement.
  24. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
  25. Leak test the fittings using J 42220 .