GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Flushing

Tools Required

    • 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 Flush Adapter Kit

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 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 J 45268 fitting O-rings. Refer to O-Ring Replacement .

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

Reverse Flushing Setup

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

    Important: Inspect and lubricate J 45268 fitting O-rings. Refer to O-Ring Replacement .

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

Flush Procedure

    Important: Warmer engine or ambient temperatures decreases refrigerant recovery time during the A/C flush procedure.

  1. Recover refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove thermal expansion valve (TXV). Refer to Thermal Expansion Valve Replacement .
  3. Install TXV stud onto J 45268-115.
  4. Install new sealing washers onto evaporator core. Refer to Sealing Washer Replacement .
  5. Install J 45268-115 in place of TXV.

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

  6. Install TXV mounting bolts.

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

  7. Install new washers onto liquid line and suction hose. Refer to Sealing Washer Replacement .
  8. Connect liquid line and suction hose to J 45268-115.
  9. Install TXV block fitting nut.

    10. Tighten
    Tighten nut to 27 N·m (20 lb ft).

  10. Remove A/C compressor. Refer to Air Conditioning Compressor Replacement .
  11. Remove A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement .

    12. Object Number: 787687 Size: SH

    Important: The filter inside J 45268-1 is serviceable. Remove and discard check valve from the filter.

  12. Service filter with ACDelco P/N GF 470, before each flush.

    13. Important: Install new sealing washers onto compressor hose assembly. Refer to Sealing Washer Replacement .

    Assure that suction and discharge ports on J 45268-10 correspond to suction and discharge ports on compressor hose assembly.

  13. Install J 45268-10 to compressor hose assembly.
  14. Connect J 45268-1 flush filter to J 45268-7 flush adapter.
  15. Connect blue hose from J 43600 to J 45268-1 flush filter adapter.
  16. Connect red hose from J 43600 to J 45268-8 flush adapter.

    17. Important: Close valve on external refrigerant tank, before starting flush process.

  17. Flush A/C system. Follow instructions supplied with J 43600 .
  18. Disconnect red hose from J 43600 to J 45268-8 flush adapter.
  19. Disconnect blue hose from J 43600 to J 45268-1 flush filter adapter.
  20. Disconnect J 45268-1 flush filter from J 45268-10 flush adapter.
  21. Remove J 45268-10 from compressor hose assembly.

    22. Important: Flushing will remove all 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. 22.1. Remove A/C compressor drain plug.
    22.2. Drain PAG oil from A/C compressor. Rotate compressor input shaft to assist in draining the PAG oil from compressor.
    22.3. Add the total system capacity of PAG oil to A/C compressor. Refer to Refrigerant System Capacities .

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

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

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

    Important: A new service compressor is shipped with a full charge of PAG oil. Refer to Refrigerant System Capacities .

  23. Install A/C compressor. Refer to Air Conditioning Compressor Replacement .
  24. Install new A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement .
  25. Remove TXV block fitting nut.
  26. Disconnect liquid line and suction line from J 45268-115.
  27. Remove TXV bolts retaining J 45268-115.
  28. Remove J 45268-115.
  29. Inspect TXV for debris. Clean or replace as needed.
  30. Install TXV. Refer to Thermal Expansion Valve Replacement .
  31. Evacuate and recharge A/C system. Refer to Refrigerant Recovery and Recharging .
  32. Leak test fittings using J 42220 .