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Repair Instructions: Flushing

NOTE:

This procedure is not used in Europe.

Special Tools

For equivalent regional tools. Refer to Special Tools  .

NOTE:

Flushing with the GE-8800  ACR 2000 Air Conditioning Service Center is not intended to remove metal from the A/C system.

Flushing is intended to remove the following:

    NOTE:

    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 GE-45268  Flush Adapter Kit onto the J45268-115.
  4. Install the J45268-115 in place of the TXV.
    5. CAUTION:

    Refer to Fastener Caution .

  5. Install the TXV mounting bolts.

    Tighten 

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

  6. Connect the evaporator line to the J45268-115.
  7. Install the TXV block fitting nut.

    Tighten 

    Tighten the bolts to 17 N.m (12.5 lb ft).

  8. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (LEA) .
  9. Install J45268-10 to the A/C compressor hose assembly.
  10. Install the nut and bolt from the J 45268  Flush Adapter Kit to the J45268-10 and compressor hose assembly.

    Tighten 

    Tighten the bolts to 17 N.m (12.5 lb ft).

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

    Perform the following procedure:

      Fig 1: View Of A/C Filter & Check Valve
      GM787687Courtesy of GENERAL MOTORS COMPANY
      NOTE:

      The filter inside GE45268-1 is serviceable. Remove and discard the check valve from the filter.

    1. Service the filter with AC Delco P/NGF470, before each flush.
    2. Install the port plugs GE45268-9 onto the GE45268-10.
    3. Install the fitting GE45268-7 onto the GE45268-10.
    4. Install the fitting GE45268-8 onto the GE45268-10.
    5. Connect GE45268-1 flush filter to the suction port of GE45268-7 flush adapter.
    6. Connect the blue hose from the GE-8800  ACR 2000 Air Conditioning Service Center to the GE45268-1 flush filter adapter.
    7. Connect the red hose from the GE-8800  ACR 2000 Air Conditioning Service Center to the GE45268-8 flush adapter.
  12. Reverse flow refrigerant flush is recommended for desiccant bag failure. Replace the A/C condenser when the A/C flush is complete and perform the following procedure:
      NOTE:

      The filter inside GE45268-1 is serviceable. Remove and discard the check valve from the filter.

    1. Service the filter with ACDelco P/NGF470, before each flush.
    2. Install the port plugs GE45268-9 onto the GE45268-10.
    3. Install the fitting GE45268-7 onto the GE45268-10.
    4. Install the fitting GE45268-8 onto the GE45268-10.
    5. Connect GE45268-1 flush filter to the discharge port of GE45268-7 flush adapter.
    6. Connect the blue hose from GE-8800  ACR 2000 Air Conditioning Service Center to the GE45268-1 flush filter adapter.
    7. Connect the red hose from GE-8800  ACR 2000 Air Conditioning Service Center to the GE45268-8 flush adapter.
    13. NOTE:

    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 GE-8800  ACR 2000 Air Conditioning Service Center.
  14. Disconnect the red hose on the GE-8800  ACR 2000 Air Conditioning Service Center from the GE45268-10.
  15. Disconnect the blue hose on the GE-8800  ACR 2000 Air Conditioning Service Center from the GE45268-1.
  16. Remove GE45268-1 from the GE45268-10.
  17. Remove the GE45268-10 from the A/C compressor hose assembly.
    18. NOTE:

    The A/C system must be replenished with the correct amount of PAG oil.

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

  18. If you will reinstall the removed A/C compressor, perform the following procedure:
    1. Remove the A/C compressor drain plug.
    2. Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor.
    3. Install the A/C compressor drain plug.

      Tighten 

      Tighten the drain plug to 16 N.m (12 lb ft).

    4. Add the total system capacity of PAG oil to the A/C compressor. Refer to Approximate Fluid Capacities .
  19. If you will replace the A/C compressor after flushing the system, perform the following procedure:
    1. Determine if the new service compressor is shipped with PAG oil. Refer to the Approximate Fluid Capacities .
    2. If the service compressor is shipped with PAG oil, DO NOT drain the new PAG oil from the compressor.
    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 Approximate Fluid Capacities .
    4. Add the calculated amount to the compressor, as needed.
    20. NOTE:

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

  20. Add one bottle of GE-41447  Leak Detection Dye directly to the A/C Compressor.
  21. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (LEA) .
  22. Remove GE45268-115.
  23. Inspect the TXV for debris. Clean or replace as needed.
  24. Install the TXV. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement .
  25. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  26. Leak test the fittings using GE-42220  Universal 12V Leak Detection Lamp.
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