GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Grand Prix 🢒 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:

    • 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 TXV. Refer to 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 J 45268-10 to the A/C compressor hose assembly.
  10. Install the nut and bolt from the J 45268 kit to the J 45268-10 and compressor hose assembly.

    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 J 45268-10.
    11.3. Install the fitting J 45268-7 onto the J 45268-10.
    11.4. Install the fitting J 45268-8 onto the J 45268-10.
    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 J 45268-10.
    12.3. Install the fitting J 45268-7 onto the J 45268-10.
    12.4. Install the fitting J 45268-8 onto the J 45268-10.
    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 J 45268-10.
  15. Disconnect the blue hose on the J 43600 from the J 45268-1.
  16. Remove J 45268-1 from the J 45268-10.
  17. Remove the J 45268-10 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. Remove the A/C compressor drain plug.
    18.2. Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor.
    18.3. Install the A/C compressor drain plug.

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

    18.4. 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. Determine if the new service compressor is shipped with PAG oil. Refer to the Refrigerant System Capacities .
    19.2. If the service compressor is shipped with PAG oil, DO NOT drain the new PAG oil from the compressor.
    19.3. 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 .
    19.4.  Add the calculated amount to the compressor, as needed.

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

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