Repair Instructions: Flushing

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Oldsmobile Silhouette, and 2003 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

J 43600 Air Conditioning Service Center
J 45268 Flush Adapter Kit. See Special Tools and Equipment .
J 41447 Leak Detection Dye. See Special Tools and Equipment .
J 41459 Leak Detection Dye Injector. See Special Tools and Equipment .
J 42220 Universal 12V Leak Detection Lamp. See Special Tools and Equipment .

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.

Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING .
Remove the TXV. Refer to THERMAL EXPANSION VALVE REPLACEMENT .
Install J 45268-103 in place of the TXV.
Remove the auxiliary TXV. Refer to THERMAL EXPANSION VALVE REPLACEMENT - AUXILIARY .
Install J 45268-107 in place of the auxiliary TXV.
Remove the A/C compressor. Refer to COMPRESSOR REPLACEMENT .
Install J 45268-5 to the discharge hose.
Install J 45268-4 to the suction hose.
Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil.
Important: The filter inside J 45268-1 is serviceable. Remove and discard the check valve from the filter.
1. 9.1 Service the filter with AC Delco P/N GF 470, before each flush.
2. 9.2 Connect J 45268-1 to the suction port of J 45268-4.
3. 9.3 Connect the blue hose from J 43600 to J 45268-1 flush filter adapter.
4. 9.4 Connect the red hose from J 43600 to J 45268-5 flush adapter.
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:

Fig 1: Removing Valve From Filter
Courtesy of GENERAL MOTORS CORP.

Important: The filter inside J 45268-1 is serviceable.
1. 10.1 Service the filter with AC Delco P/N GF 470, before each flush.
2. 10.2 Connect J 45268-1 to the discharge port of J 45268-5.
3. 10.3 Connect the blue hose from J 43600 to J 45268-1 flush filter adapter.
4. 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.
Flush the front A/C system. Follow the instructions supplied with the J 43600.
Important: Flush the front A/C system before flushing the auxiliary A/C system.
If the vehicle is equipped with rear A/C, flush the auxiliary A/C system separately.
1. 12.1 Remove J 45268-107 from the auxiliary evaporator core.
2. 12.2 Remove J 45268-103.
3. 12.3 Install J 45268-103 to the auxiliary evaporator core.
4. 12.4 Install J 45268-107.
Flush the auxiliary A/C system. Follow the instructions supplied with J 43600.
Remove J 45268-5 from the discharge hose.
Remove J 45268-4 from the suction hose.
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.
If the removed A/C compressor is being reinstalled, perform the following procedure:
1. 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.
2. 16.2 Add the total system capacity of PAG oil to the A/C compressor. Refer to REFRIGERANT SYSTEM CAPACITIES .
If you will replace the A/C compressor after flushing the system, perform the following procedure:
1. 17.1 A new service compressor is shipped with PAG oil. Refer to the REFRIGERANT SYSTEM CAPACITIES .
2. 17.2 If the service compressor is shipped with PAG oil, DO NOT drain the new PAG oil from the compressor.
3. 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.
Install the A/C compressor. Refer to COMPRESSOR REPLACEMENT .
Remove J 45268-103.
Inspect the TXV for debris. Clean or replace as needed.
Install the auxiliary TXV. Refer to THERMAL EXPANSION VALVE REPLACEMENT - AUXILIARY .
Remove J 45268-107.
Inspect the TXV for debris. Clean or replace as needed.
Install the TXV. Refer to THERMAL EXPANSION VALVE REPLACEMENT .
Evacuate and recharge the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING .
Important: Flushing will remove the fluorescent leak detection dye from the A/C system.
Add one bottle of J 41447 using J 41459.
Leak test the fittings using J 42220.