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Vauxhall Workshop Service and Repair Manuals

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Heater Core Replacement - Left Hand Drive > < Floor Rear Air Outlet Duct Replacement - Right Side

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Flushing

Special Tools

•  BO-42220   Universal 12V Leak Detection Lamp
•  GE-41447   R-134A A/C Tracer Dye Box of 24
•  GE-45268   A/C Flush Adapter Kit

For equivalent regional tools, refer to Special Tools .


Note:  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


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

Note:  Inspect and lubricate GE-45268   adapter kit fitting O-rings. Refer to Air Conditioning O-Ring Seal Replacement .
1. Install both GE-45268-9   fitting O-rings onto the GE-45268-10   adapter .
2. Install the GE-45268-8   fitting O-ring onto the suction side of the GE-45268-10   adapter .
3. Install the GE-45268-7   fitting O-ring onto the discharge side of the GE-45268-10   adapter .

Reverse Flushing Setup


Note: 
•  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:
•  Inspect and lubricate the GE-45268   adapter kit fitting O-rings. Refer to Air Conditioning O-Ring Seal Replacement .

1. Install both GE-45268-9   fitting O-rings onto the GE-45268-10   adapter .
2. Install the GE-45268-8   fitting O-ring onto the suction side of the GE-45268-10   adapter .
3. Install the GE-45268-7   fitting O-ring onto the discharge side of the GE-45268-10   adapter .

Flush Procedure


Note:  Warmer engine or ambient temperatures decreases 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. Install the TXV stud onto the GE-45268-115   adapter .
4. Install new sealing washers onto the evaporator core. Refer to Air Conditioning O-Ring Seal Replacement .
5. Install the GE-45268-115   adapter in place of the TXV using an oversized seal washer.

Caution: Refer to Fastener Caution .
6. Install the TXV mounting bolts and tighten to 15 N·m (11 lb in) .
7. Install new washers onto the liquid line and the suction hose. Refer to Air Conditioning O-Ring Seal Replacement .
8. Connect the liquid line and the suction hose to the GE-45268-115   adapter using an oversized seal washer.
9. Install the TXV block fitting nut and tighten to 19 N·m (14 lb in) .
10. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .

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11. Remove the A/C refrigerant filter (1). Refer to Air Conditioning (AC) Refrigerant Filter Replacement .

Note:  The filter inside the GE-45268-1   adapter is serviceable. Remove and DISCARD check valve from the filter.
12. Service the filter before each flush.

Note:  Assure that the suction and discharge ports on G-45268-10 correspond to the suction and discharge ports on the compressor hose assembly.
13. Install new sealing washers onto the A/C compressor and the condenser hose. Refer to Air Conditioning O-Ring Seal Replacement . Assure that the suction and discharge ports on the GE-45268-10   adapter correspond to the suction and the discharge ports on the A/C compressor to the condenser hose.
14. Install the GE-45268-10   filter adapter to the A/C compressor to the condenser hose.
15. Connect the GE-45268-1   filter to the G-45268-7   adapter .
16. Connect the blue hose from the A/C filling device to the GE-45268   adapter .
17. Connect the red hose from the A/C filling device to the GE-45268   adapter .
18. Disconnect the blue hose from the A/C filling device to the GE-45268-1   adapter .
19. Disconnect the GE-45268-1   adapter from the GE-45268-10   adapter .
20. Remove the GE-45268-10   adapter from the A/C compressor to the condenser hose.

Note:  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.
21. If you will reinstall the removed A/C compressor, perform the following procedure:
  •  Remove the A/C compressor drain plug. Refer to Air Conditioning Compressor Oil Drain Plug Replacement .
  •  Drain PAG oil from the A/C compressor. Rotate compressor input shaft to assist in draining the PAG oil from compressor.
  •  Add the total system capacity of PAG oil to the A/C compressor. Refer to Refrigerant System Specifications .
  •  Add one bottle of the GE-41447   tracer dye .
  •  Install the A/C compressor drain plug. Refer to Air Conditioning Compressor Oil Drain Plug Replacement .

Note:  Flushing will remove fluorescent leak detection dye from A/C system.
22. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .
23. Install the new A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement .
24. Remove the TXV block fitting nut.
25. Disconnect the liquid line and the suction line from the GE-45268-115   adapter .
26. Remove the TXV bolts retaining GE-45268-115   adapter .
27. Remove the GE-45268-115   adapter .
28. Inspect the TXV for debris. Clean or replace as needed.
30. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
31. Leak test fittings using the BO-42220   lamp .

Heater Core Replacement - Left Hand Drive > < Floor Rear Air Outlet Duct Replacement - Right Side