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Flush Procedure

WARNING: This page is about a different car, the 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Warmer engine or ambient temperatures 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. Fig 1: Thermal Expansion Valve
    GM1552176Courtesy of GENERAL MOTORS CORP.
  3. Install the stud onto the J 45268-115.
  4. Install new sealing washers onto the evaporator core. Refer to Air Conditioning System Seal Replacement .
  5. Install J 45268-115 in place of the TXV.
    CAUTION: Refer to Fastener Caution .
  6. Install TXV mounting bolts.

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

  7. Install new washers onto the condenser tube and evaporator hose. Refer to Air Conditioning System Seal Replacement .
  8. Connect the condenser tube and evaporator hose to the J 45268-115.
  9. Install the TXV block fitting nut.

    Tighten:  Tighten the nut to 20 N.m (15 lb ft).

  10. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  11. Remove the A/C refrigerant filter. Refer to Air Conditioning Evaporator Thermal Expansion Valve Screen Replacement .
    12. Fig 2: View Of A/C Filter And Check Valve
    GM787687Courtesy of GENERAL MOTORS CORP.
    NOTE: The filter inside J 45268-1 is serviceable. Remove and discard the check valve from the filter.
  12. Service the filter with AC Delco P/N GF 470, before each flush.
    13. NOTE: Install new sealing washers onto the compressor hose assembly. Refer to Air Conditioning System Seal Replacement .
    Assure that the suction and discharge ports on the J 45268-10 correspond to the suction and discharge ports on the compressor hose assembly.
  13. Install the J 45268-10 to the compressor hose assembly.
  14. Connect the J 45268-1 flush filter to the J 45268-7 flush adapter.
    15. Fig 3: Flush Filter & Flush Adapter
    GM1552177Courtesy of GENERAL MOTORS CORP.
  15. Connect the blue hose from the J 43600  . See Special Tools .
  16. Connect the red hose from the J 43600  . See Special Tools .
    17. NOTE: Close the valve on the external refrigerant tank, before starting the flush process.
  17. Flush the A/C system. Follow the instructions supplied with the J 43600  . See Special Tools .
  18. Disconnect the red hose from the J 43600  . See Special Tools .
  19. Disconnect the blue hose from the J 43600  . See Special Tools .
  20. Disconnect the J 45268-1 flush filter from the J 45268-10 flush adapter.
  21. Remove the J 45268-10 from the compressor hose assembly.
    22. NOTE: 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.
  22. If you will reinstall the removed A/C compressor, perform the following procedure:
      Fig 4: A/C Compressor Drain Plug
      GM1480098Courtesy of GENERAL MOTORS CORP.
    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. Add the total system capacity of PAG oil to the crankcase of the A/C compressor. Refer to Refrigerant System Capacities .
      4. NOTE: Flushing will remove the fluorescent leak detection dye from the A/C system.
    4. Add one bottle of J 41447  . See Special Tools .
    5. Install the A/C compressor drain plug.

      Tighten:  Tighten the drain plug to 15 N.m (11 lb ft).

    23. NOTE: A new service compressor is shipped with a partial charge of PAG oil. Refer to Refrigerant System Capacities .
  23. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  24. Install the A/C refrigerant filter. Refer to Air Conditioning Evaporator Thermal Expansion Valve Screen Replacement .
  25. Remove the TXV block fitting nut.
  26. Disconnect the condenser tube and evaporator hose from the J45268-115.
    27. Fig 5: Thermal Expansion Valve
    GM1552176Courtesy of GENERAL MOTORS CORP.
  27. Remove the TXV bolts retaining the J 45268-115.
  28. Remove the J 45268-115.
  29. Inspect the TXV for debris. Clean or replace as needed.
  30. Install the TXV. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement .
  31. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  32. Leak test the fittings using J 42220  .
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