GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Cobalt 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Flushing

Special Tools

    • J 41447 R-134A A/C Tracer Dye - Box of 24
    • J 42220 Universal 12V Leak Detection Lamp
    • J 43600 ACR 2000 Air Conditioning Service Center
    • J 45268 A/C Flushing Adapter Kit

Important: Flushing with the J 43600 .

Flushing is intended to remove the following:

    • Contaminated polyalkylene glycol (PAG) oil
    • Desiccant, following a desiccant bag failure
    • Overcharge of PAG oil
    • Refrigerant contamination

Forward Flushing Setup

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


    Object Number: 1162447 Size: SH

    Important: Inspect and lubricate the sealing washers J 45268 . Refer to Sealing Washer Replacement.

  1. Install both J 45268-9 (2) onto the J 45268-10 (3).
  2. Install the J 45268-7 (4) onto the suction side of the J 45268-10 (3).
  3. Install the J 45268-8 (1) onto the discharge side of the J 45268-10 (3).

Reverse Flushing Setup

    Important: Reverse flow refrigerant flush is recommended for desiccant bag failure. Replace the condenser/receiver dehydrator assembly when the A/C flush is complete and perform the following procedure:


    Object Number: 1211671 Size: SH

    Important: Inspect and lubricate the J 45268 . Refer to Sealing Washer Replacement.

  1. Install both J 45268-9  (2) onto the J 45268-10 (3).
  2. Install the J 45268-8 (1) onto the suction side of the J 45268-10 (3).
  3. Install the J 45268-7 (4) onto the discharge side of the J 45268-10 (3).

Flush Procedure

    Important: 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. Object Number: 1552176 Size: SH
  3. Install the stud onto the J 45268-115.
  4. Install new sealing washers onto the evaporator core. Refer to Sealing Washer Replacement.

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

  5. Install J 45268-115 in place of the TXV.
  6. Install TXV mounting bolts.

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

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

    10. 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. Object Number: 787687 Size: SH

    Important: 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. Important: Install new sealing washers onto the compressor hose assembly. Refer to Sealing Washer 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. Object Number: 1552177 Size: SH
  15. Connect the blue hose from the J 43600 .
  16. Connect the red hose from the J 43600 .

    17. Important: 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 .
  18. Disconnect the red hose from the J 43600 .
  19. Disconnect the blue hose from the J 43600 .
  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. 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.

  22. If you will reinstall the removed A/C compressor, perform the following procedure:

    23. Object Number: 1480098 Size: SH
    22.1. Remove the A/C compressor drain plug.
    22.2. Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor.
    22.3. Add the total system capacity of PAG oil to the crankcase of the A/C compressor. Refer to Refrigerant System Capacities.

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

    22.4. Add one bottle of J 41447 .
    22.5. Install the A/C compressor drain plug.

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

    Important: 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. Object Number: 1552176 Size: SH
  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 .